From 0a6a4d13a8c91a472e778f6f8ba240e6dfe64aae Mon Sep 17 00:00:00 2001
From: Devil <dasblueyeddevil@gmail.com>
Date: Mon, 13 Jul 2026 20:49:20 -0400
Subject: [PATCH] fix(#652): reset shared stall timer on completed working rep

The shared stall countdown (WorkoutCoordinator.stallStartTime) is armed
by both low-velocity motion and firmware DELOAD_OCCURRED, but until now
was cancelled only by a metric above 10 mm/s. PR #650 cleared the
verbal-cue defer deadline at the completed-rep boundary on the same
premise: a completed working rep is authoritative proof the athlete is
back in motion.

Without resetting the stall timer at that boundary, a countdown started
at a turnaround, brief pause, or firmware de-load could survive a
subsequent valid rep and later triggerAutoStop() -> handleSetCompletion(),
prematurely ending a set the athlete is still performing.

Add resetStallTimer() alongside deferAutoStopDeadlineMs = 0L inside the
repCountAfter > repCountBefore branch of handleRepNotification. This is
the narrow shared fix for both stall arms and preserves issue #256: a
pending first working rep has not completed, so its timer remains armed
and the existing 5-second stall guard still fires.

TDD evidence:
- RED characterization (Issue 652 test) reproduced on main@0f00f4b:
  stallStartTime remained set after a completed second working rep.
- GREEN after the fix; full :shared:testAndroidHostTest suite (2442
  tests) and issue #256 tests stay green.

No thresholds, setting semantics, AMRAP position auto-stop, VBT Auto-End,
or unrelated code changed. Stall Detection remains independent from
autoEndOnVelocityLoss.

Fixes #652
---
 .../manager/ActiveSessionEngine.kt            |  6 +++
 .../manager/DWSMWorkoutLifecycleTest.kt       | 52 +++++++++++++++++++
 2 files changed, 58 insertions(+)

diff --git a/shared/src/commonMain/kotlin/com/devil/phoenixproject/presentation/manager/ActiveSessionEngine.kt b/shared/src/commonMain/kotlin/com/devil/phoenixproject/presentation/manager/ActiveSessionEngine.kt
index 643fb0952..af0a56e0a 100644
--- a/shared/src/commonMain/kotlin/com/devil/phoenixproject/presentation/manager/ActiveSessionEngine.kt
+++ b/shared/src/commonMain/kotlin/com/devil/phoenixproject/presentation/manager/ActiveSessionEngine.kt
@@ -1100,6 +1100,12 @@ class ActiveSessionEngine(
             // motion; let normal AMRAP / stall auto-stop resume by zeroing the
             // deadline (the source-of-truth field).
             deferAutoStopDeadlineMs = 0L
+            // Issue #652: the same completed-rep boundary is authoritative for
+            // the shared stall countdown (both DELOAD_OCCURRED and low-velocity
+            // arms write to coordinator.stallStartTime). Without this, a stale
+            // countdown started at a turnaround, brief pause, or firmware de-load
+            // can survive a subsequent valid rep and later auto-complete the set.
+            resetStallTimer()
 
             // Capture rep boundary timestamp BEFORE scoring so scoreCurrentRep()
             // and processBiomechanicsForRep() both see the correct metric window.
diff --git a/shared/src/commonTest/kotlin/com/devil/phoenixproject/presentation/manager/DWSMWorkoutLifecycleTest.kt b/shared/src/commonTest/kotlin/com/devil/phoenixproject/presentation/manager/DWSMWorkoutLifecycleTest.kt
index 77ce980a7..6316d1adb 100644
--- a/shared/src/commonTest/kotlin/com/devil/phoenixproject/presentation/manager/DWSMWorkoutLifecycleTest.kt
+++ b/shared/src/commonTest/kotlin/com/devil/phoenixproject/presentation/manager/DWSMWorkoutLifecycleTest.kt
@@ -1204,6 +1204,58 @@ class DWSMWorkoutLifecycleTest {
         harness.cleanup()
     }
 
+    @Test
+    fun `Issue 652 - completed Echo rep cancels an armed stall timer`() = runTest {
+        val harness = DWSMTestHarness(this)
+        harness.fakeBleRepo.simulateConnect("Vee_Test")
+        harness.dwsm.updateWorkoutParameters(
+            WorkoutParameters(
+                programMode = ProgramMode.Echo,
+                echoLevel = EchoLevel.HARDER,
+                reps = 10,
+                warmupReps = 0,
+                stallDetectionEnabled = true,
+                isAMRAP = false,
+                isJustLift = false,
+            ),
+        )
+        harness.dwsm.startWorkout(skipCountdown = true)
+        advanceUntilIdle()
+        completeWarmupReps(harness, warmupTarget = 3, workingTarget = 10)
+        completeFirstWorkingRep(harness, warmupTarget = 3, workingTarget = 10)
+        advanceUntilIdle()
+
+        harness.fakeBleRepo.emitDeloadOccurred()
+        advanceUntilIdle()
+        assertNotNull(harness.dwsm.coordinator.stallStartTime)
+
+        harness.fakeBleRepo.emitRepNotification(
+            RepNotification(
+                topCounter = 5,
+                completeCounter = 5,
+                repsRomCount = 3,
+                repsRomTotal = 3,
+                repsSetCount = 2,
+                repsSetTotal = 10,
+                rangeTop = 800f,
+                rangeBottom = 0f,
+                rawData = ByteArray(24),
+                timestamp = 5L,
+            ),
+        )
+        advanceUntilIdle()
+
+        assertEquals(2, harness.dwsm.coordinator.repCount.value.workingReps)
+        assertEquals(
+            null,
+            harness.dwsm.coordinator.stallStartTime,
+            "A completed working rep proves motion resumed and must cancel the stale stall countdown",
+        )
+        assertFalse(harness.dwsm.coordinator.isCurrentlyStalled)
+        assertIs<WorkoutState.Active>(harness.dwsm.coordinator.workoutState.value)
+        harness.cleanup()
+    }
+
     @Test
     fun `Issue 267 Just Lift warmup to working rep transitions without failed stall state`() = runTest {
         val harness = DWSMTestHarness(this)