visionA/local-tool/server/internal/driver/kneron/kl720_driver.go

package kneron

import (
	"bufio"
	"encoding/base64"
	"encoding/json"
	"fmt"
	"io"
	"os"
	"os/exec"
	"path/filepath"
	"runtime"
	"strings"
	"sync"
	"time"

	"visiona-local/server/internal/driver"
	"visiona-local/server/pkg/logger"
)

// LogFunc is a function that writes a log line to both stderr and
// the WebSocket broadcaster.  When nil, logs go only to stderr.
type LogFunc func(level, msg string)

// KneronDriver implements driver.DeviceDriver for Kneron NPU devices
// (KL520, KL720, etc.). It delegates hardware operations to a Python
// subprocess (kneron_bridge.py) that communicates via JSON-RPC over
// stdin/stdout.
type KneronDriver struct {
	info        driver.DeviceInfo
	connected   bool
	inferring   bool
	modelLoaded string
	chipType    string // "KL520" or "KL720" — derived from info.Type
	mu          sync.Mutex

	scriptPath     string
	pythonCmd      *exec.Cmd
	stdin          io.WriteCloser
	stdout         *bufio.Scanner
	pythonReady    bool
	logBroadcaster *logger.Broadcaster
	needsReset     bool // true on first connect after server start to clear stale models
}

// NewKneronDriver creates a new KneronDriver with the given device info and
// path to the kneron_bridge.py script. Works for any Kneron chip variant.
func NewKneronDriver(info driver.DeviceInfo, scriptPath string) *KneronDriver {
	chip := "KL520"
	if strings.Contains(strings.ToLower(info.Type), "kl720") {
		chip = "KL720"
	}
	return &KneronDriver{
		info:       info,
		scriptPath: scriptPath,
		chipType:   chip,
		needsReset: true,
	}
}

// SetLogBroadcaster attaches a log broadcaster so that bridge stderr
// and driver messages are forwarded to the frontend.
func (d *KneronDriver) SetLogBroadcaster(b *logger.Broadcaster) {
	d.logBroadcaster = b
}

// driverLog writes a log message to stderr and the broadcaster.
func (d *KneronDriver) driverLog(level, format string, args ...interface{}) {
	msg := fmt.Sprintf(format, args...)
	fmt.Fprintf(os.Stderr, "%s\n", msg)
	if d.logBroadcaster != nil {
		d.logBroadcaster.Push(level, msg)
	}
}

// NewKL720Driver is a backward-compatible alias for NewKneronDriver.
// Deprecated: Use NewKneronDriver instead.
func NewKL720Driver(info driver.DeviceInfo, scriptPath string) *KneronDriver {
	return NewKneronDriver(info, scriptPath)
}

// KL720Driver is a backward-compatible type alias for KneronDriver.
// Deprecated: Use KneronDriver instead.
type KL720Driver = KneronDriver

// resolvePython finds the best Python interpreter using the package-level resolver.
func (d *KneronDriver) resolvePython() string {
	return ResolvePython(d.scriptPath)
}

// startPython launches the Python bridge subprocess and waits for the
// "ready" signal on stdout.
func (d *KneronDriver) startPython() error {
	pythonBin := d.resolvePython()
	scriptDir := filepath.Dir(d.scriptPath)

	cmd := exec.Command(pythonBin, d.scriptPath)

	// On macOS with Apple Silicon, Kneron SDK requires x86_64 (Rosetta 2).
	// The venv should already contain the correct architecture Python.
	// Set DYLD_LIBRARY_PATH so libkplus.dylib can be found.
	cmd.Env = append(os.Environ(),
		"PYTHONUNBUFFERED=1",
	)

	// Add library path for native kp module if lib directory exists.
	libDir := filepath.Join(scriptDir, "lib")
	if _, err := os.Stat(libDir); err == nil {
		if runtime.GOOS == "darwin" {
			cmd.Env = append(cmd.Env, "DYLD_LIBRARY_PATH="+libDir)
		} else {
			cmd.Env = append(cmd.Env, "LD_LIBRARY_PATH="+libDir)
		}
	}

	// On Windows, ensure libusb-1.0.dll can be found by adding the install
	// directory to PATH (installer places the DLL there).
	if runtime.GOOS == "windows" {
		installDir := filepath.Dir(scriptDir)
		cmd.Env = append(cmd.Env,
			fmt.Sprintf("PATH=%s;%s;%s", installDir, scriptDir, os.Getenv("PATH")))
	}

	stdinPipe, err := cmd.StdinPipe()
	if err != nil {
		return fmt.Errorf("failed to create stdin pipe: %w", err)
	}

	stdoutPipe, err := cmd.StdoutPipe()
	if err != nil {
		stdinPipe.Close()
		return fmt.Errorf("failed to create stdout pipe: %w", err)
	}

	// Capture stderr from the Python bridge: forward each line to both
	// os.Stderr and the WebSocket broadcaster so it shows in the frontend.
	stderrPipe, err := cmd.StderrPipe()
	if err != nil {
		stdinPipe.Close()
		stdoutPipe.Close()
		return fmt.Errorf("failed to create stderr pipe: %w", err)
	}

	if err := cmd.Start(); err != nil {
		stdinPipe.Close()
		return fmt.Errorf("failed to start python bridge (%s): %w", pythonBin, err)
	}

	// Forward bridge stderr line-by-line to os.Stderr + broadcaster.
	go func() {
		scanner := bufio.NewScanner(stderrPipe)
		for scanner.Scan() {
			line := scanner.Text()
			fmt.Fprintln(os.Stderr, line)
			if d.logBroadcaster != nil {
				d.logBroadcaster.Push("DEBUG", line)
			}
		}
	}()

	d.pythonCmd = cmd
	d.stdin = stdinPipe
	d.stdout = bufio.NewScanner(stdoutPipe)

	// Increase scanner buffer for large inference responses.
	d.stdout.Buffer(make([]byte, 0, 64*1024), 1024*1024)

	// Wait for the ready signal from the Python process.
	if d.stdout.Scan() {
		var resp map[string]interface{}
		if err := json.Unmarshal([]byte(d.stdout.Text()), &resp); err == nil {
			if status, ok := resp["status"].(string); ok && status == "ready" {
				d.pythonReady = true
				return nil
			}
		}
	}

	// If we didn't get a ready signal, clean up and report failure.
	d.stopPython()
	return fmt.Errorf("python bridge did not send ready signal")
}

// sendCommand sends a JSON command to the Python subprocess and returns
// the parsed JSON response.
func (d *KneronDriver) sendCommand(cmd map[string]interface{}) (map[string]interface{}, error) {
	if !d.pythonReady {
		return nil, fmt.Errorf("python bridge is not running")
	}

	data, err := json.Marshal(cmd)
	if err != nil {
		return nil, fmt.Errorf("failed to marshal command: %w", err)
	}

	// Write the JSON command followed by a newline.
	if _, err := fmt.Fprintf(d.stdin, "%s\n", data); err != nil {
		return nil, fmt.Errorf("failed to write to python bridge: %w", err)
	}

	// Read the response line.
	if !d.stdout.Scan() {
		if err := d.stdout.Err(); err != nil {
			return nil, fmt.Errorf("failed to read from python bridge: %w", err)
		}
		return nil, fmt.Errorf("python bridge closed unexpectedly")
	}

	var resp map[string]interface{}
	if err := json.Unmarshal([]byte(d.stdout.Text()), &resp); err != nil {
		return nil, fmt.Errorf("failed to parse python response: %w", err)
	}

	// Check for error responses from the bridge.
	if errMsg, ok := resp["error"].(string); ok {
		return nil, fmt.Errorf("python bridge error: %s", errMsg)
	}

	return resp, nil
}

// stopPython kills the Python subprocess and cleans up resources.
func (d *KneronDriver) stopPython() {
	d.pythonReady = false

	if d.stdin != nil {
		d.stdin.Close()
		d.stdin = nil
	}

	if d.pythonCmd != nil && d.pythonCmd.Process != nil {
		d.pythonCmd.Process.Kill()
		d.pythonCmd.Wait()
		d.pythonCmd = nil
	}

	d.stdout = nil
}

// Info returns the current device information.
func (d *KneronDriver) Info() driver.DeviceInfo {
	d.mu.Lock()
	defer d.mu.Unlock()
	return d.info
}

// Connect starts the Python bridge subprocess and connects to the Kneron device.
// On the first connect after server start, the device is reset to clear any
// stale model from a previous session.
func (d *KneronDriver) Connect() error {
	d.mu.Lock()

	if d.connected {
		d.mu.Unlock()
		return nil
	}

	needsReset := d.needsReset
	d.info.Status = driver.StatusConnecting

	// Start the Python bridge process.
	if err := d.startPython(); err != nil {
		d.info.Status = driver.StatusError
		d.mu.Unlock()
		return fmt.Errorf("failed to start hardware bridge: %w", err)
	}

	// Send connect command to the bridge.
	resp, err := d.sendCommand(map[string]interface{}{
		"cmd":         "connect",
		"port":        d.info.Port,
		"index":       0,
		"device_type": d.info.Type,
	})
	if err != nil {
		d.stopPython()
		d.info.Status = driver.StatusError
		d.mu.Unlock()
		return fmt.Errorf("failed to connect to device: %w", err)
	}

	d.connected = true
	d.needsReset = false
	d.info.Status = driver.StatusConnected

	if fw, ok := resp["firmware"].(string); ok {
		d.info.FirmwareVer = fw
	}
	d.mu.Unlock()

	// First connect after server start: reset device to clear stale models.
	//
	// BOTH KL520 and KL720 需要 reset：
	//
	// - KL720 是 flash-based 裝置，firmware 和 model 會保留在 flash，reset
	//   清 stale model 才有意義。
	//
	// - KL520 雖然是 USB Boot 裝置（RAM-based firmware，斷電即清），理論上
	//   每次 connect 是 clean state。但實測發現若 session 間 firmware 殘留
	//   （fw=KDP2 Comp/U 而非 Loader），直接走 load_model + inference 會
	//   100% 炸 ApiKPException Error 15 (SEND_DATA_TOO_LARGE)。只有走
	//   reset → reboot 到 Loader → 重新載 firmware 到 Comp/U 的完整流程，
	//   才能得到能正常 inference 的 session。
	//
	//   成本：KL520 reset + firmware load + reconnect ~15-20s（macOS 實測）。
	//   Windows 上可能更久；若 HTTP connect timeout 60s 不夠，需調高或改
	//   非同步 connect pattern。
	if needsReset {
		d.driverLog("INFO", "[kneron] first connect after server start — resetting %s to clear stale session...", d.chipType)
		if err := d.restartBridge(); err != nil {
			d.driverLog("WARN", "[kneron] reset on connect failed (non-fatal): %v", err)
		} else {
			d.driverLog("INFO", "[kneron] device reset complete — clean state ready")
		}
	}

	return nil
}

// Disconnect stops the Python bridge and disconnects from the device.
func (d *KneronDriver) Disconnect() error {
	d.mu.Lock()
	defer d.mu.Unlock()

	if !d.connected {
		return nil
	}

	// Try to send disconnect command if Python is running.
	if d.pythonReady {
		d.sendCommand(map[string]interface{}{"cmd": "disconnect"})
	}

	d.stopPython()
	d.connected = false
	d.inferring = false
	d.info.Status = driver.StatusDisconnected

	return nil
}

// IsConnected returns whether the driver is currently connected.
func (d *KneronDriver) IsConnected() bool {
	d.mu.Lock()
	defer d.mu.Unlock()
	return d.connected
}

// restartBridge resets the Kneron device and restarts the Python bridge.
//
// The KL520 USB Boot mode only allows loading one model per firmware
// session. To load a different model we must:
//  1. Send a "reset" command via the current bridge — this calls
//     kp.core.reset_device() which forces the device back to Loader
//     (USB Boot) state, wiping firmware + model from RAM.
//  2. Kill the Python bridge process.
//  3. Wait for the device to re-enumerate on USB (~8 s).
//  4. Start a fresh Python bridge.
//  5. Send "connect" which reloads firmware from scratch.
//
// After this the device is in a clean state ready for load_model.
//
// Caller must NOT hold d.mu.
func (d *KneronDriver) restartBridge() error {
	d.mu.Lock()
	port := d.info.Port
	d.modelLoaded = ""

	// Step 1: Ask the running bridge to reset the device.
	if d.pythonReady {
		d.driverLog("INFO", "[kneron] sending reset command to device...")
		d.sendCommand(map[string]interface{}{"cmd": "reset"})
		// Ignore errors — the device may have already disconnected.
	}

	// Step 2: Kill the bridge process.
	d.stopPython()
	d.mu.Unlock()

	// Step 3: Wait for USB device to re-enumerate after hardware reset.
	// The reset causes the device to drop off USB and reappear as a
	// Loader-mode device. This typically takes 5-8 seconds.
	d.driverLog("INFO", "[kneron] bridge stopped, waiting for USB re-enumerate after reset...")
	time.Sleep(8 * time.Second)

	d.mu.Lock()
	defer d.mu.Unlock()

	// Step 4: Start a fresh Python bridge.
	d.driverLog("INFO", "[kneron] starting new bridge process...")
	if err := d.startPython(); err != nil {
		return fmt.Errorf("failed to restart bridge: %w", err)
	}

	// Step 5: Reconnect — firmware will be loaded fresh.
	d.driverLog("INFO", "[kneron] bridge started, reconnecting to device (port=%s)...", port)
	_, err := d.sendCommand(map[string]interface{}{
		"cmd":         "connect",
		"port":        port,
		"index":       0,
		"device_type": d.info.Type,
	})
	if err != nil {
		d.stopPython()
		return fmt.Errorf("failed to reconnect after bridge restart: %w", err)
	}
	d.driverLog("INFO", "[kneron] device reconnected after reset + bridge restart")

	return nil
}

// Flash loads a model onto the Kneron device. Progress is reported through
// the provided channel.
//
// Behavior differs by chip:
//   - KL520 (USB Boot): only one model per session. Error 40 triggers
//     a full device reset + bridge restart + firmware reload.
//   - KL720 (flash-based): models can be freely reloaded. Error 40
//     should not occur; if it does, a simple retry is attempted first.
func (d *KneronDriver) Flash(modelPath string, progressCh chan<- driver.FlashProgress) error {
	d.mu.Lock()
	d.info.Status = driver.StatusFlashing
	pythonReady := d.pythonReady
	currentModel := d.modelLoaded
	chip := d.chipType
	d.mu.Unlock()

	if !pythonReady {
		d.mu.Lock()
		d.info.Status = driver.StatusConnected
		d.mu.Unlock()
		return fmt.Errorf("hardware bridge is not running — cannot flash model")
	}

	// Same model already loaded — skip, report success
	if currentModel != "" && currentModel == modelPath {
		d.driverLog("INFO", "[kneron] model already loaded (%s), skipping reload", modelPath)
		progressCh <- driver.FlashProgress{
			Percent: 50,
			Stage:   "transferring",
			Message: "model already loaded on device",
		}
		d.mu.Lock()
		d.info.Status = driver.StatusConnected
		d.mu.Unlock()
		progressCh <- driver.FlashProgress{Percent: 100, Stage: "done", Message: "Flash complete (model already loaded)"}
		return nil
	}

	// Try loading the model
	progressCh <- driver.FlashProgress{
		Percent: 5,
		Stage:   "preparing",
		Message: "preparing... loading model to device",
	}

	d.mu.Lock()
	_, err := d.sendCommand(map[string]interface{}{
		"cmd":  "load_model",
		"path": modelPath,
	})
	d.mu.Unlock()

	// Handle retryable errors (error 40, broken pipe).
	if err != nil {
		errMsg := err.Error()
		d.driverLog("WARN", "[kneron] load_model failed: %s", errMsg)

		isRetryable := strings.Contains(errMsg, "Error code: 40") ||
			strings.Contains(errMsg, "SECOND_MODEL") ||
			strings.Contains(errMsg, "broken pipe") ||
			strings.Contains(errMsg, "USB_TIMEOUT")

		if isRetryable {
			if chip == "KL720" {
				// KL720: error 40 should not occur. Try a simple retry
				// without full bridge restart first.
				d.driverLog("WARN", "[kneron] KL720 unexpected retryable error, retrying without restart...")
				progressCh <- driver.FlashProgress{
					Percent: 5,
					Stage:   "preparing",
					Message: "preparing... retrying model load",
				}

				d.mu.Lock()
				_, err = d.sendCommand(map[string]interface{}{
					"cmd":  "load_model",
					"path": modelPath,
				})
				d.mu.Unlock()

				// If still failing, fall back to bridge restart as last resort.
				if err != nil {
					d.driverLog("WARN", "[kneron] KL720 retry failed: %v, falling back to bridge restart...", err)
					if restartErr := d.restartBridge(); restartErr != nil {
						d.mu.Lock()
						d.info.Status = driver.StatusConnected
						d.mu.Unlock()
						return fmt.Errorf("failed to reset device: %w", restartErr)
					}
					d.mu.Lock()
					d.info.Status = driver.StatusFlashing
					_, err = d.sendCommand(map[string]interface{}{
						"cmd":  "load_model",
						"path": modelPath,
					})
					d.mu.Unlock()
				}
			} else {
				// KL520: error 40 means a model is already loaded in this
				// USB Boot session. Must reset device + reload firmware.
				d.driverLog("WARN", "[kneron] KL520 retryable error, restarting bridge...")
				progressCh <- driver.FlashProgress{
					Percent: 5,
					Stage:   "preparing",
					Message: "preparing... resetting device for new model",
				}

				if restartErr := d.restartBridge(); restartErr != nil {
					d.driverLog("ERROR", "[kneron] restartBridge failed: %v", restartErr)
					d.mu.Lock()
					d.info.Status = driver.StatusConnected
					d.mu.Unlock()
					return fmt.Errorf("failed to reset device: %w", restartErr)
				}

				d.driverLog("INFO", "[kneron] bridge restarted, retrying load_model...")
				d.mu.Lock()
				d.info.Status = driver.StatusFlashing
				_, err = d.sendCommand(map[string]interface{}{
					"cmd":  "load_model",
					"path": modelPath,
				})
				d.mu.Unlock()
			}
		}
	}

	if err != nil {
		d.driverLog("ERROR", "[kneron] load_model ultimately failed: %v", err)
		d.mu.Lock()
		d.info.Status = driver.StatusConnected
		d.mu.Unlock()
		return fmt.Errorf("failed to load model: %w", err)
	}
	d.driverLog("INFO", "[kneron] load_model succeeded: %s", modelPath)

	// Simulate remaining flash progress stages (the Kneron SDK does not
	// provide granular progress, so we approximate it after the model
	// has been loaded successfully).
	type stage struct {
		name     string
		duration time.Duration
		startPct int
		endPct   int
	}

	stages := []stage{
		{"transferring", 2 * time.Second, 10, 80},
		{"verifying", 1 * time.Second, 80, 95},
		{"finalizing", 500 * time.Millisecond, 95, 99},
	}

	// KL720 is faster (USB 3.0, no firmware reload needed)
	if chip == "KL720" {
		stages = []stage{
			{"transferring", 1 * time.Second, 10, 80},
			{"verifying", 500 * time.Millisecond, 80, 95},
			{"finalizing", 200 * time.Millisecond, 95, 99},
		}
	}

	for _, s := range stages {
		steps := (s.endPct - s.startPct) / 5
		if steps < 1 {
			steps = 1
		}
		interval := s.duration / time.Duration(steps)
		for i := 0; i <= steps; i++ {
			pct := s.startPct + (s.endPct-s.startPct)*i/steps
			progressCh <- driver.FlashProgress{
				Percent: pct,
				Stage:   s.name,
				Message: fmt.Sprintf("%s... %d%%", s.name, pct),
			}
			time.Sleep(interval)
		}
	}

	d.mu.Lock()
	d.modelLoaded = modelPath
	d.info.FlashedModel = modelPath
	d.info.Status = driver.StatusConnected
	d.mu.Unlock()

	progressCh <- driver.FlashProgress{Percent: 100, Stage: "done", Message: "Flash complete"}

	return nil
}

// StartInference begins continuous inference mode.
func (d *KneronDriver) StartInference() error {
	d.mu.Lock()
	defer d.mu.Unlock()

	if !d.connected {
		return fmt.Errorf("device not connected")
	}

	d.inferring = true
	d.info.Status = driver.StatusInferencing
	return nil
}

// StopInference stops continuous inference mode.
func (d *KneronDriver) StopInference() error {
	d.mu.Lock()
	defer d.mu.Unlock()

	d.inferring = false
	d.info.Status = driver.StatusConnected
	return nil
}

// ReadInference reads the latest inference result. This is equivalent to
// calling RunInference with nil image data.
func (d *KneronDriver) ReadInference() (*driver.InferenceResult, error) {
	return d.RunInference(nil)
}

// RunInference runs inference on the provided image data and returns
// the result. If imageData is nil, the bridge will run inference on
// a default/empty input.
func (d *KneronDriver) RunInference(imageData []byte) (*driver.InferenceResult, error) {
	d.mu.Lock()
	pythonReady := d.pythonReady
	d.mu.Unlock()

	if !pythonReady {
		return nil, fmt.Errorf("hardware bridge is not running — device may not be connected")
	}

	// Encode image data as base64 for transmission to Python.
	imageB64 := ""
	if imageData != nil {
		imageB64 = base64.StdEncoding.EncodeToString(imageData)
	}

	d.mu.Lock()
	resp, err := d.sendCommand(map[string]interface{}{
		"cmd":          "inference",
		"image_base64": imageB64,
	})
	d.mu.Unlock()
	if err != nil {
		return nil, fmt.Errorf("inference failed: %w", err)
	}

	return parseInferenceResult(resp)
}

// parseInferenceResult converts a JSON response map into an InferenceResult.
func parseInferenceResult(resp map[string]interface{}) (*driver.InferenceResult, error) {
	// Re-marshal to JSON and unmarshal into the struct for clean conversion.
	data, err := json.Marshal(resp)
	if err != nil {
		return nil, fmt.Errorf("failed to marshal response: %w", err)
	}

	var result driver.InferenceResult
	if err := json.Unmarshal(data, &result); err != nil {
		return nil, fmt.Errorf("failed to parse inference result: %w", err)
	}

	return &result, nil
}

// GetModelInfo returns information about the currently loaded model.
func (d *KneronDriver) GetModelInfo() (*driver.ModelInfo, error) {
	d.mu.Lock()
	defer d.mu.Unlock()

	if d.modelLoaded == "" {
		return nil, fmt.Errorf("no model loaded")
	}

	return &driver.ModelInfo{
		ID:       d.modelLoaded,
		Name:     d.modelLoaded,
		LoadedAt: time.Now(),
	}, nil
}