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1 Commits

Author SHA1 Message Date
Rob Colbert
009863cf2b fix: resolve drone heartbeat timeouts and JWT expiration bugs
This commit addresses two interrelated issues causing drones to
de-register and users to be forcibly signed out:

## Heartbeat Timeout Fixes

1. Move heartbeat interval to a Web Worker (not subject to browser
   tab throttling). Chrome throttles setInterval in background tabs
   to ~1/min, which causes the 19s heartbeat to miss the drone's
   timeout timer. The Web Worker fires reliably regardless of tab
   visibility.

2. Add visibilitychange handler: when the tab becomes visible again,
   send an immediate heartbeat to reset the drone's timer after any
   throttling that may have occurred.

3. Fix onReleaseSessionLock to clear the heartbeat timer. Previously,
   releasing the lock left the 60s timer running, causing a spurious
   timeout and status emit after the lock was already released.

4. Increase drone heartbeat timeout from 60s to 120s. With the Web
   Worker fix, heartbeats should be reliable, but doubling the timeout
   provides a generous safety margin.

5. Add socket disconnect/reconnect handlers on the drone side. On
   disconnect, clear the heartbeat timer. On reconnect, re-emit drone
   status so the platform knows the drone is alive.

6. Configure Socket.IO pingInterval/pingTimeout explicitly (25s/60s)
   instead of relying on defaults.

## JWT Expiration Fixes

1. Increase WebToken DB record expiration from 1 hour to 7 days. The
   1-hour expiration was the real session lifetime gate (the JWT crypto
   exp was already 24h), and it was far too aggressive for a dev tool.

2. Fix web /auth/renew-token endpoint to use req.user from the session
   cookie instead of verifyJsonWebToken(req.body.token). This eliminates
   the catch-22 where an expired token cannot be used to request its
   own renewal.

3. Fix token refresh response parsing. The API v1 renew-token endpoint
   returns { success: true, token } at the top level, but the frontend
   was looking for json.data?.token, causing every refresh to fail.

4. Add proactive token refresh: check the JWT exp claim before each
   request and refresh if expiring within 5 minutes. This avoids
   unnecessary 401 errors and the resulting socket disconnections.

5. Update socket JWT on token renewal via a callback registered in
   App.tsx. This ensures that future socket reconnections use the new
   token instead of the expired one.

## Files Modified

- gadget-code/frontend/src/workers/heartbeat.worker.ts (NEW)
- gadget-code/frontend/src/lib/socket.ts
- gadget-code/frontend/src/lib/api.ts
- gadget-code/frontend/src/App.tsx
- gadget-code/src/services/session.ts
- gadget-code/src/controllers/auth.ts
- gadget-code/src/services/socket.ts
- gadget-drone/src/gadget-drone.ts
2026-05-11 17:46:09 -04:00