From b9165ac4bdb5a330176b5e996652d4a23dba19db Mon Sep 17 00:00:00 2001
From: Neil <4138956+nwparker@users.noreply.github.com>
Date: Tue, 26 May 2026 20:24:25 -0700
Subject: [PATCH] fix: tear down timed-out speech workers (#2880)

---
 src/main/speech/stt-service.test.ts | 33 +++++++++++++++++
 src/main/speech/stt-service.ts      | 56 ++++++++++++++++++++++++-----
 2 files changed, 80 insertions(+), 9 deletions(-)

diff --git a/src/main/speech/stt-service.test.ts b/src/main/speech/stt-service.test.ts
index 6bd82d3c2..fb4561b1d 100644
--- a/src/main/speech/stt-service.test.ts
+++ b/src/main/speech/stt-service.test.ts
@@ -29,6 +29,10 @@ const { MockWorker, getCreatedWorkerCount, getLastWorker, resetWorkers } = vi.ho
       return this
     }
 
+    listenerCount(eventName: string): number {
+      return this.listeners.get(eventName)?.size ?? 0
+    }
+
     removeAllListeners(): this {
       this.listeners.clear()
       return this
@@ -239,4 +243,33 @@ describe('SttService', () => {
       vi.useRealTimers()
     }
   })
+
+  it('does not retain or reuse a worker that timed out while stopping', async () => {
+    vi.useFakeTimers()
+    try {
+      const service = new SttService({
+        getModelState: vi.fn().mockResolvedValue({ id: 'model-a', status: 'ready' }),
+        getModelDir: vi.fn().mockReturnValue('/tmp/model-a')
+      } as never)
+
+      await service.startDictation('model-a', vi.fn(), undefined, 'desktop')
+      const firstWorker = getLastWorker()
+      expect(firstWorker).toBeDefined()
+      firstWorker!.emitStoppedOnStop = false
+
+      const stopPromise = service.stopDictation('desktop')
+      await vi.advanceTimersByTimeAsync(60_000)
+      await stopPromise
+
+      expect(firstWorker!.terminated).toBe(true)
+      expect(firstWorker!.listenerCount('message')).toBe(0)
+
+      await service.startDictation('model-a', vi.fn(), undefined, 'desktop')
+
+      expect(getCreatedWorkerCount()).toBe(2)
+      expect(getLastWorker()).not.toBe(firstWorker)
+    } finally {
+      vi.useRealTimers()
+    }
+  })
 })
diff --git a/src/main/speech/stt-service.ts b/src/main/speech/stt-service.ts
index e31218645..e943565bf 100644
--- a/src/main/speech/stt-service.ts
+++ b/src/main/speech/stt-service.ts
@@ -1,3 +1,5 @@
+/* eslint-disable max-lines -- Why: speech worker ownership, warm reuse, and
+timeout teardown must stay co-located so dictation lifecycle state cannot drift. */
 import { Worker } from 'worker_threads'
 import { join } from 'path'
 import { app } from 'electron'
@@ -232,26 +234,62 @@ export class SttService {
     const worker = this.worker
     worker.postMessage({ type: 'stop' })
 
+    let forcedTeardown = false
     await new Promise<void>((resolve) => {
-      const timeout = setTimeout(() => {
-        worker.terminate()
+      let settled = false
+      let timeout: ReturnType<typeof setTimeout> | null = null
+
+      const cleanup = (): void => {
+        if (timeout) {
+          clearTimeout(timeout)
+          timeout = null
+        }
+        worker.off('message', onStopped)
+      }
+
+      const finish = (): void => {
+        if (settled) {
+          return
+        }
+        settled = true
+        cleanup()
         resolve()
-      }, STOP_DICTATION_TIMEOUT_MS)
+      }
 
       const onStopped = (msg: { type: string; text?: string; error?: string }) => {
         if (msg.type === 'stopped') {
-          clearTimeout(timeout)
-          worker.off('message', onStopped)
-          resolve()
+          finish()
         }
       }
+
+      timeout = setTimeout(() => {
+        if (settled) {
+          return
+        }
+        settled = true
+        forcedTeardown = true
+        cleanup()
+        // Why: a worker that cannot finish dictation is no longer reusable; do
+        // not keep it in the warm-worker slot or retain its message listeners.
+        worker.removeAllListeners()
+        void worker.terminate().finally(resolve)
+      }, STOP_DICTATION_TIMEOUT_MS)
+
       worker.on('message', onStopped)
     })
 
     if (this.worker === worker) {
-      this.activeOwner = null
-      this.eventSink = null
-      this.scheduleIdleTeardown()
+      if (forcedTeardown) {
+        this.worker = null
+        this.activeModelId = null
+        this.activeHotwordsFilePath = undefined
+        this.activeOwner = null
+        this.eventSink = null
+      } else {
+        this.activeOwner = null
+        this.eventSink = null
+        this.scheduleIdleTeardown()
+      }
     }
   }