From b98fae9b610d9ef6e18dcf4edde8d400ed3aaaee Mon Sep 17 00:00:00 2001
From: Sanchal Ranjan <84386862+sanchalr@users.noreply.github.com>
Date: Thu, 23 Jul 2026 13:38:05 -0500
Subject: [PATCH] fix(autopilot): give full-cycle dispatch a 30-minute timeout
 floor (#2852)

Dispatch timeout was derived as interval*2 with a 5-minute floor, tuned
for light per-interval work. A full autopilot cycle routinely needs more
than 10 minutes at common intervals, so healthy full cycles were killed
mid-run. Full-cycle dispatch now gets a 30-minute floor; lighter
dispatches keep the interval-derived budget.

Adds a regression test for the full-cycle floor.
---
 src/commands/autopilot-timeout.ts    |  9 +++++++++
 src/commands/autopilot.ts            |  7 +++++--
 test/autopilot-fanout-wiring.test.ts | 16 ++++++++++++++++
 3 files changed, 30 insertions(+), 2 deletions(-)
 create mode 100644 src/commands/autopilot-timeout.ts

diff --git a/src/commands/autopilot-timeout.ts b/src/commands/autopilot-timeout.ts
new file mode 100644
index 000000000..0ef6b5b59
--- /dev/null
+++ b/src/commands/autopilot-timeout.ts
@@ -0,0 +1,9 @@
+export function resolveAutopilotDispatchTimeoutMs(
+  baseIntervalSeconds: number,
+  fullCycle: boolean,
+): number {
+  const intervalDerivedTimeoutMs = Math.max(baseIntervalSeconds * 2 * 1000, 300_000);
+  return fullCycle
+    ? Math.max(intervalDerivedTimeoutMs, 1_800_000)
+    : intervalDerivedTimeoutMs;
+}
diff --git a/src/commands/autopilot.ts b/src/commands/autopilot.ts
index 82979fb12..4f0ca39a0 100644
--- a/src/commands/autopilot.ts
+++ b/src/commands/autopilot.ts
@@ -38,6 +38,7 @@ import { logSelfUpgrade } from '../core/audit/self-upgrade-audit.ts';
 import { detectInstallMethod } from './upgrade.ts';
 import { evaluateQuietHours } from '../core/minions/quiet-hours.ts';
 import { inspectLock } from '../core/db-lock.ts';
+import { resolveAutopilotDispatchTimeoutMs } from './autopilot-timeout.ts';
 
 /**
  * v0.37.7.0 #1162 — classify autopilot reconnect-loop errors.
@@ -689,7 +690,7 @@ export async function runAutopilot(engine: BrainEngine, args: string[]) {
         const queue = new MinionQueue(engine);
         const slotMs = Math.floor(Date.now() / (baseInterval * 1000)) * baseInterval * 1000;
         const slot = new Date(slotMs).toISOString();
-        const timeoutMs = Math.max(baseInterval * 2 * 1000, 300_000);
+        const timeoutMs = resolveAutopilotDispatchTimeoutMs(baseInterval, false);
 
         // ── v0.40 D17: per-source freshness check ────────────────────
         // Runs first; independent of score gate. Submits a 'sync' job per
@@ -931,7 +932,9 @@ export async function runAutopilot(engine: BrainEngine, args: string[]) {
           const result = await dispatchPerSource(engine, queue, {
             repoPath,
             slot,
-            timeoutMs,
+            // Full cycles can outlive short daemon intervals. Keep lighter dispatches
+            // interval-derived while giving per-source consolidation enough time.
+            timeoutMs: resolveAutopilotDispatchTimeoutMs(baseInterval, true),
             fanoutMax,
             jsonMode,
           });
diff --git a/test/autopilot-fanout-wiring.test.ts b/test/autopilot-fanout-wiring.test.ts
index addf8dbe3..213b5d7c7 100644
--- a/test/autopilot-fanout-wiring.test.ts
+++ b/test/autopilot-fanout-wiring.test.ts
@@ -15,6 +15,7 @@
 import { describe, expect, test } from 'bun:test';
 import { readFileSync } from 'fs';
 import { join } from 'path';
+import { resolveAutopilotDispatchTimeoutMs } from '../src/commands/autopilot-timeout.ts';
 
 const AUTOPILOT_SRC = readFileSync(
   join(import.meta.dir, '..', 'src', 'commands', 'autopilot.ts'),
@@ -48,6 +49,21 @@ describe('autopilot.ts ↔ dispatchPerSource wiring', () => {
     expect(Math.abs(dispatchIdx - fullCycleIdx)).toBeLessThan(3000);
   });
 
+  test('applies the 30-minute timeout floor only to full-cycle dispatch', () => {
+    const baseIntervalSeconds = 60;
+    const intervalDerivedTimeoutMs = Math.max(baseIntervalSeconds * 2 * 1000, 300_000);
+
+    expect(resolveAutopilotDispatchTimeoutMs(baseIntervalSeconds, true)).toBeGreaterThanOrEqual(30 * 60_000);
+    expect(resolveAutopilotDispatchTimeoutMs(baseIntervalSeconds, false)).toBe(intervalDerivedTimeoutMs);
+
+    expect(AUTOPILOT_SRC).toContain(
+      'const timeoutMs = resolveAutopilotDispatchTimeoutMs(baseInterval, false);',
+    );
+    expect(AUTOPILOT_SRC).toMatch(
+      /dispatchPerSource\(engine, queue, \{[\s\S]{0,300}timeoutMs: resolveAutopilotDispatchTimeoutMs\(baseInterval, true\)/,
+    );
+  });
+
   test('updates lastFullCycleAt on dispatch (so the 60-min floor is honored)', () => {
     // After the dispatchPerSource call, the lastFullCycleAt module var
     // must update so the next tick doesn't immediately re-fan-out.