fix(exec): keep timeout classification deterministic

src/process/supervisor/supervisor.test.ts

@@ -1,3 +1,4 @@
+import { performance } from "node:perf_hooks";
 import { afterEach, beforeEach, describe, expect, it, vi } from "vitest";
 import type { SpawnProcessAdapter } from "./types.js";
 
@@ -266,6 +267,58 @@ describe("process supervisor", () => {
     expect(exit.timedOut).toBe(true);
   });
 
+  it("classifies a natural close after a missed overall deadline as timed out", async () => {
+    vi.useFakeTimers();
+    const nowSpy = vi.spyOn(performance, "now").mockReturnValue(1_000);
+    const adapter = createStubChildAdapter();
+    createChildAdapterMock.mockResolvedValue(adapter);
+
+    const supervisor = createProcessSupervisor();
+    const run = await spawnChild(supervisor, {
+      sessionId: "s-timeout-race",
+      argv: createSilentIdleArgv(),
+      timeoutMs: 10,
+      stdinMode: "pipe-closed",
+    });
+
+    const exitPromise = run.wait();
+    nowSpy.mockReturnValue(1_011);
+    adapter.settle(0);
+
+    const exit = await exitPromise;
+    expect(adapter.killMock).not.toHaveBeenCalled();
+    expect(exit.reason).toBe("overall-timeout");
+    expect(exit.timedOut).toBe(true);
+  });
+
+  it("uses the refreshed no-output deadline when a missed timer races natural close", async () => {
+    vi.useFakeTimers();
+    const nowSpy = vi.spyOn(performance, "now").mockReturnValue(1_000);
+    const adapter = createStubChildAdapter();
+    createChildAdapterMock.mockResolvedValue(adapter);
+
+    const supervisor = createProcessSupervisor();
+    const run = await spawnChild(supervisor, {
+      sessionId: "s-no-output-race",
+      argv: createSilentIdleArgv(),
+      timeoutMs: 100,
+      noOutputTimeoutMs: 10,
+      stdinMode: "pipe-closed",
+    });
+
+    const exitPromise = run.wait();
+    nowSpy.mockReturnValue(1_005);
+    adapter.emitStdout("progress");
+    nowSpy.mockReturnValue(1_016);
+    adapter.settle(0);
+
+    const exit = await exitPromise;
+    expect(adapter.killMock).not.toHaveBeenCalled();
+    expect(exit.reason).toBe("no-output-timeout");
+    expect(exit.noOutputTimedOut).toBe(true);
+    expect(exit.timedOut).toBe(true);
+  });
+
   it("can stream output without retaining it in RunExit payload", async () => {
     const adapter = createStubChildAdapter();
     createChildAdapterMock.mockResolvedValue(adapter);

src/process/supervisor/supervisor.ts

@@ -1,4 +1,5 @@
 import crypto from "node:crypto";
+import { performance } from "node:perf_hooks";
 import { normalizeOptionalString } from "@openclaw/normalization-core/string-coerce";
 import { getShellConfig } from "../../agents/shell-utils.js";
 import { createChildAdapter } from "./adapters/child.js";
@@ -63,6 +64,34 @@ function isTimeoutReason(reason: TerminationReason) {
   return reason === "overall-timeout" || reason === "no-output-timeout";
 }
 
+function resolveElapsedTimeoutReason(params: {
+  nowMs: number;
+  overallTimeoutDeadlineMs: number | null;
+  noOutputTimeoutDeadlineMs: number | null;
+}): TerminationReason | null {
+  const elapsedDeadlines: Array<{ reason: TerminationReason; deadlineMs: number }> = [];
+  if (params.overallTimeoutDeadlineMs !== null && params.nowMs >= params.overallTimeoutDeadlineMs) {
+    elapsedDeadlines.push({
+      reason: "overall-timeout",
+      deadlineMs: params.overallTimeoutDeadlineMs,
+    });
+  }
+  if (
+    params.noOutputTimeoutDeadlineMs !== null &&
+    params.nowMs >= params.noOutputTimeoutDeadlineMs
+  ) {
+    elapsedDeadlines.push({
+      reason: "no-output-timeout",
+      deadlineMs: params.noOutputTimeoutDeadlineMs,
+    });
+  }
+  if (elapsedDeadlines.length === 0) {
+    return null;
+  }
+  elapsedDeadlines.sort((a, b) => a.deadlineMs - b.deadlineMs);
+  return elapsedDeadlines[0].reason;
+}
+
 export function createProcessSupervisor(): ProcessSupervisor {
   const registry = createRunRegistry();
   const active = new Map<string, ActiveRun>();
@@ -122,6 +151,8 @@ export function createProcessSupervisor(): ProcessSupervisor {
 
     const overallTimeoutMs = clampTimeout(input.timeoutMs);
     const noOutputTimeoutMs = clampTimeout(input.noOutputTimeoutMs);
+    let overallTimeoutDeadlineMs: number | null = null;
+    let noOutputTimeoutDeadlineMs: number | null = null;
 
     const setForcedReason = (reason: TerminationReason) => {
       if (forcedReason) {
@@ -143,6 +174,7 @@ export function createProcessSupervisor(): ProcessSupervisor {
       if (!noOutputTimeoutMs || settled) {
         return;
       }
+      noOutputTimeoutDeadlineMs = performance.now() + noOutputTimeoutMs;
       if (noOutputTimer) {
         clearTimeout(noOutputTimer);
       }
@@ -210,11 +242,13 @@ export function createProcessSupervisor(): ProcessSupervisor {
       };
 
       if (overallTimeoutMs) {
+        overallTimeoutDeadlineMs = performance.now() + overallTimeoutMs;
         timeoutTimer = setTimeout(() => {
           requestCancel("overall-timeout");
         }, overallTimeoutMs);
       }
       if (noOutputTimeoutMs) {
+        noOutputTimeoutDeadlineMs = performance.now() + noOutputTimeoutMs;
         noOutputTimer = setTimeout(() => {
           requestCancel("no-output-timeout");
         }, noOutputTimeoutMs);
@@ -237,16 +271,22 @@ export function createProcessSupervisor(): ProcessSupervisor {
 
       const waitPromise = (async (): Promise<RunExit> => {
         const result = await adapter.wait();
+        const deadlineReason = resolveElapsedTimeoutReason({
+          nowMs: performance.now(),
+          overallTimeoutDeadlineMs,
+          noOutputTimeoutDeadlineMs,
+        });
+        const terminalReason = forcedReason ?? deadlineReason;
         if (settled) {
           return {
-            reason: forcedReason ?? "exit",
+            reason: terminalReason ?? "exit",
             exitCode: result.code,
             exitSignal: result.signal,
             durationMs: Date.now() - startedAtMs,
             stdout,
             stderr,
-            timedOut: isTimeoutReason(forcedReason ?? "exit"),
-            noOutputTimedOut: forcedReason === "no-output-timeout",
+            timedOut: isTimeoutReason(terminalReason ?? "exit"),
+            noOutputTimedOut: terminalReason === "no-output-timeout",
           };
         }
         settled = true;
@@ -255,7 +295,7 @@ export function createProcessSupervisor(): ProcessSupervisor {
         active.delete(runId);
 
         const reason: TerminationReason =
-          forcedReason ?? (result.signal != null ? ("signal" as const) : ("exit" as const));
+          terminalReason ?? (result.signal != null ? ("signal" as const) : ("exit" as const));
         const exit: RunExit = {
           reason,
           exitCode: result.code,
@@ -263,8 +303,8 @@ export function createProcessSupervisor(): ProcessSupervisor {
           durationMs: Date.now() - startedAtMs,
           stdout,
           stderr,
-          timedOut: isTimeoutReason(forcedReason ?? reason),
-          noOutputTimedOut: forcedReason === "no-output-timeout",
+          timedOut: isTimeoutReason(terminalReason ?? reason),
+          noOutputTimedOut: terminalReason === "no-output-timeout",
         };
         registry.finalize(runId, {
           reason: exit.reason,