fix(daemon): exit on uncaught exceptions instead of swallowing them

src/daemon/fatal-error.test.ts

@@ -0,0 +1,104 @@
+import { afterEach, describe, expect, test } from "bun:test";
+import { unlinkSync } from "fs";
+import { tmpdir } from "os";
+import { join } from "path";
+import { exitOnUncaughtException } from "./fatal-error";
+
+const fatalErrorModule = JSON.stringify(join(import.meta.dir, "fatal-error.ts"));
+
+const fixturePaths: string[] = [];
+
+afterEach(() => {
+  while (fixturePaths.length > 0) {
+    try {
+      unlinkSync(fixturePaths.pop()!);
+    } catch {
+      // Best effort cleanup of temp fixtures.
+    }
+  }
+});
+
+/** Run a fixture script in a real subprocess so process.exit is for real. */
+async function runFixture(source: string): Promise<{
+  exitCode: number;
+  stdout: string;
+  stderr: string;
+}> {
+  const scriptPath = join(
+    tmpdir(),
+    `routstrd-fatal-error-fixture-${crypto.randomUUID()}.ts`,
+  );
+  fixturePaths.push(scriptPath);
+  await Bun.write(scriptPath, source);
+  const proc = Bun.spawn(["bun", scriptPath], {
+    stdout: "pipe",
+    stderr: "pipe",
+  });
+  const [stdout, stderr] = await Promise.all([
+    new Response(proc.stdout).text(),
+    new Response(proc.stderr).text(),
+  ]);
+  const exitCode = await proc.exited;
+  return { exitCode, stdout, stderr };
+}
+
+describe("exitOnUncaughtException", () => {
+  test("reports the error and exits with code 1", () => {
+    let exitCode: number | undefined;
+    const stderrLines: string[] = [];
+    const originalConsoleError = console.error;
+    console.error = (...args: unknown[]) => {
+      stderrLines.push(args.map(String).join(" "));
+    };
+    try {
+      exitOnUncaughtException(new Error("boom"), (code) => {
+        exitCode = code;
+      });
+    } finally {
+      console.error = originalConsoleError;
+    }
+    expect(exitCode).toBe(1);
+    expect(stderrLines.join("\n")).toContain("boom");
+  });
+
+  test("handles non-Error thrown values", () => {
+    let exitCode: number | undefined;
+    const originalConsoleError = console.error;
+    console.error = () => {};
+    try {
+      exitOnUncaughtException("string failure", (code) => {
+        exitCode = code;
+      });
+    } finally {
+      console.error = originalConsoleError;
+    }
+    expect(exitCode).toBe(1);
+  });
+});
+
+describe("installGlobalErrorHandlers (subprocess)", () => {
+  test("an uncaught exception exits the process with code 1", async () => {
+    const { exitCode, stderr } = await runFixture(`
+      import { installGlobalErrorHandlers } from ${fatalErrorModule};
+      installGlobalErrorHandlers();
+      setTimeout(() => {
+        throw new Error("boom-uncaught");
+      }, 10);
+    `);
+    expect(exitCode).toBe(1);
+    expect(stderr).toContain("boom-uncaught");
+  });
+
+  test("an unhandled rejection is logged without exiting", async () => {
+    const { exitCode, stdout } = await runFixture(`
+      import { installGlobalErrorHandlers } from ${fatalErrorModule};
+      installGlobalErrorHandlers();
+      Promise.reject(new Error("boom-rejection"));
+      setTimeout(() => {
+        console.log("STILL-ALIVE");
+      }, 50);
+    `);
+    expect(exitCode).toBe(0);
+    expect(stdout).toContain("STILL-ALIVE");
+  });
+});

src/daemon/fatal-error.ts

@@ -0,0 +1,48 @@
+import { logger } from "../utils/logger";
+
+/**
+ * Report an unrecoverable error, then exit.
+ *
+ * The daemon runs detached under a supervisor (pm2 via `routstrd service
+ * install`, or the spawning CLI). An uncaught exception means the call stack
+ * unwound unexpectedly mid-operation and process state can no longer be
+ * trusted. Swallowing it once left a daemon alive with nothing listening
+ * while it held both wallet PID locks, so every later start failed on the
+ * lock and liveness-only supervisors never restarted it. Exiting lets the
+ * supervisor bring up a healthy process instead.
+ *
+ * The file logger writes synchronously, so the record survives the exit.
+ * The error is mirrored to stderr because the daemon's stdout/stderr are
+ * redirected to debug.log, which is what the CLI surfaces when the daemon
+ * exits early and what pm2 captures. process.exit() runs the synchronous
+ * PID-lock exit hooks registered by claimPidFile, releasing the wallet
+ * locks on the way out.
+ *
+ * `exit` is injectable for tests.
+ */
+export function exitOnUncaughtException(
+  error: unknown,
+  exit: (code: number) => void = (code) => process.exit(code),
+): void {
+  logger.error("UNCAUGHT EXCEPTION:", error);
+  // Full error object (not just .message): this path means a bug, so the
+  // stack is the most useful thing to have in debug.log.
+  console.error("UNCAUGHT EXCEPTION:", error);
+  exit(1);
+}
+
+/**
+ * Install the process-level error handlers. Called once at daemon module
+ * load, before main() runs.
+ *
+ * Only uncaught exceptions are fatal. An unhandled rejection means a
+ * promise's failure went unobserved; the stack was not unwound and the
+ * process is still in a consistent state, so it is logged and the daemon
+ * keeps serving.
+ */
+export function installGlobalErrorHandlers(): void {
+  process.on("uncaughtException", (error) => exitOnUncaughtException(error));
+  process.on("unhandledRejection", (reason) => {
+    logger.error("UNHANDLED REJECTION:", reason);
+  });
+}

src/daemon/index.ts

@@ -67,17 +67,14 @@ import {
   legacyCocodPidPath,
   legacyCocodSocketPath,
 } from "./wallet/paths";
+import { installGlobalErrorHandlers } from "./fatal-error";
 
 // Global error handlers — the daemon is spawned detached with stdout/stderr
 // redirected to a file, so without these, uncaught async errors would kill
-// the process silently. Log to the file logger before exiting.
-process.on("uncaughtException", (error) => {
-  logger.error("UNCAUGHT EXCEPTION:", error);
-});
-
-process.on("unhandledRejection", (reason) => {
-  logger.error("UNHANDLED REJECTION:", reason);
-});
+// the process silently. Uncaught exceptions are fatal: the process state can
+// no longer be trusted, so the daemon logs and exits for its supervisor to
+// restart (see fatal-error.ts).
+installGlobalErrorHandlers();
 
 async function main(): Promise<void> {
   // Install signal handlers before migration and wallet startup. If a signal