bambuddy/backend/app/api/routes/camera.py

"""Camera streaming API endpoints for Bambu Lab printers."""

import asyncio
import logging
import os
import subprocess
import sys
from collections.abc import AsyncGenerator

from fastapi import APIRouter, Depends, HTTPException, Request
from fastapi.responses import Response, StreamingResponse
from sqlalchemy import select
from sqlalchemy.ext.asyncio import AsyncSession

from backend.app.core.auth import (
    RequireCameraStreamTokenIfAuthEnabled,
    RequirePermissionIfAuthEnabled,
    create_camera_stream_token,
)
from backend.app.core.database import get_db
from backend.app.core.permissions import Permission
from backend.app.models.printer import Printer
from backend.app.models.user import User
from backend.app.services.camera import (
    capture_camera_frame,
    create_tls_proxy,
    generate_chamber_image_stream,
    get_camera_port,
    get_ffmpeg_path,
    is_chamber_image_model,
    read_next_chamber_frame,
    test_camera_connection,
)
from backend.app.services.camera_fanout import (
    MjpegBroadcaster,
    get_or_create_broadcaster,
    iter_subscriber,
    shutdown_broadcaster,
)

logger = logging.getLogger(__name__)
router = APIRouter(prefix="/printers", tags=["camera"])

# Track active ffmpeg processes for cleanup
_active_streams: dict[str, asyncio.subprocess.Process] = {}

# Track active chamber image connections for cleanup
_active_chamber_streams: dict[str, tuple] = {}

# Store last frame for each printer (for photo capture from active stream)
_last_frames: dict[int, bytes] = {}

# Track last frame timestamp for each printer (for stall detection)
_last_frame_times: dict[int, float] = {}

# Track stream start times for each printer
_stream_start_times: dict[int, float] = {}

# Track active external camera streams by printer ID
_active_external_streams: set[int] = set()

# Track ALL spawned ffmpeg PIDs (persists even if _active_streams entries are removed)
# Maps PID -> spawn timestamp — used by cleanup to find truly orphaned OS processes
_spawned_ffmpeg_pids: dict[int, float] = {}

# Track disconnect events per stream_id — allows stop endpoint and cleanup
# to signal generators to stop reconnecting instead of just killing the process
_disconnect_events: dict[str, asyncio.Event] = {}

# Track last frame time per stream_id (not just per printer_id) for stale detection
_stream_last_frame_times: dict[str, float] = {}


def get_buffered_frame(printer_id: int) -> bytes | None:
    """Get the last buffered frame for a printer from an active stream.

    Returns the JPEG frame data if available, or None if no active stream.
    """
    return _last_frames.get(printer_id)


async def get_printer_or_404(printer_id: int, db: AsyncSession) -> Printer:
    """Get printer by ID or raise 404."""
    result = await db.execute(select(Printer).where(Printer.id == printer_id))
    printer = result.scalar_one_or_none()
    if not printer:
        raise HTTPException(status_code=404, detail="Printer not found")
    return printer


async def generate_chamber_mjpeg_stream(
    ip_address: str,
    access_code: str,
    model: str | None,
    fps: int = 5,
    stream_id: str | None = None,
    disconnect_event: asyncio.Event | None = None,
    printer_id: int | None = None,
) -> AsyncGenerator[bytes, None]:
    """Generate MJPEG stream from A1/P1 printer using chamber image protocol.

    This connects to port 6000 and reads JPEG frames using the Bambu binary protocol.
    """
    logger.info("Starting chamber image stream for %s (stream_id=%s, model=%s)", ip_address, stream_id, model)

    # Register disconnect event so stop endpoint can signal us
    if stream_id and disconnect_event:
        _disconnect_events[stream_id] = disconnect_event

    connection = await generate_chamber_image_stream(ip_address, access_code, fps)
    if connection is None:
        logger.error("Failed to connect to chamber image stream for %s", ip_address)
        yield (
            b"--frame\r\n"
            b"Content-Type: text/plain\r\n\r\n"
            b"Error: Camera connection failed. Check printer is on and camera is enabled.\r\n"
        )
        return

    reader, writer = connection

    # Track active connection for cleanup
    if stream_id:
        _active_chamber_streams[stream_id] = (reader, writer)

    try:
        frame_interval = 1.0 / fps if fps > 0 else 0.2
        last_frame_time = 0.0

        while True:
            # Check if client disconnected
            if disconnect_event and disconnect_event.is_set():
                logger.info("Client disconnected, stopping chamber stream %s", stream_id)
                break

            # Read next frame
            frame = await read_next_chamber_frame(reader, timeout=30.0)
            if frame is None:
                logger.warning("Chamber image stream ended for %s", stream_id)
                break

            # Save frame to buffer for photo capture and track timestamp
            if printer_id is not None:
                import time

                _last_frames[printer_id] = frame
                _last_frame_times[printer_id] = time.time()

            # Rate limiting - skip frames if needed to maintain target FPS
            current_time = asyncio.get_event_loop().time()
            if current_time - last_frame_time < frame_interval:
                continue
            last_frame_time = current_time

            # Yield frame in MJPEG format
            yield (
                b"--frame\r\n"
                b"Content-Type: image/jpeg\r\n"
                b"Content-Length: " + str(len(frame)).encode() + b"\r\n"
                b"\r\n" + frame + b"\r\n"
            )

    except asyncio.CancelledError:
        logger.info("Chamber image stream cancelled (stream_id=%s)", stream_id)
    except GeneratorExit:
        logger.info("Chamber image stream generator exit (stream_id=%s)", stream_id)
    except Exception as e:
        logger.exception("Chamber image stream error: %s", e)
    finally:
        # Remove from active streams and disconnect events
        if stream_id:
            _active_chamber_streams.pop(stream_id, None)
            _disconnect_events.pop(stream_id, None)
            _stream_last_frame_times.pop(stream_id, None)

        # Clean up frame buffer and timestamps
        if printer_id is not None:
            _last_frames.pop(printer_id, None)
            _last_frame_times.pop(printer_id, None)
            _stream_start_times.pop(printer_id, None)

        # Close the connection
        try:
            writer.close()
            await writer.wait_closed()
        except OSError:
            pass  # Connection already closed or broken; cleanup is best-effort
        logger.info("Chamber image stream stopped for %s (stream_id=%s)", ip_address, stream_id)


async def _terminate_ffmpeg(process: asyncio.subprocess.Process, stream_id: str | None = None) -> None:
    """Terminate an ffmpeg process gracefully, then kill if needed."""
    if process.returncode is not None:
        return  # Already dead
    try:
        process.terminate()
        try:
            await asyncio.wait_for(process.wait(), timeout=2.0)
        except TimeoutError:
            logger.warning("ffmpeg didn't terminate gracefully, killing (stream_id=%s)", stream_id)
            process.kill()
            await process.wait()
    except ProcessLookupError:
        pass  # Already dead
    except OSError as e:
        logger.warning("Error terminating ffmpeg: %s", e)
    _spawned_ffmpeg_pids.pop(process.pid, None)


def _summarize_ffmpeg_stderr(text: str | None) -> str:
    """Strip ffmpeg's boilerplate banner and keep only actionable lines.

    ffmpeg prints ~20 lines of version/build/configuration/lib headers before
    any actual error message. Logging the full banner on every retry floods
    the log (hundreds of lines per failed stream). This filter drops the
    banner and caps output at the last 10 meaningful lines.
    """
    if not text:
        return ""
    banner_prefixes = (
        "ffmpeg version ",
        "  built with ",
        "  configuration:",
        "  libavutil ",
        "  libavcodec ",
        "  libavformat ",
        "  libavdevice ",
        "  libavfilter ",
        "  libswscale ",
        "  libswresample ",
        "  libpostproc ",
    )
    meaningful = [ln for ln in text.splitlines() if ln.strip() and not ln.startswith(banner_prefixes)]
    return "\n".join(meaningful[-10:])


async def _read_ffmpeg_stderr(process: asyncio.subprocess.Process) -> str | None:
    """Read ffmpeg stderr for diagnostics (best-effort, non-blocking).

    Returns the stderr content with ffmpeg's boilerplate banner stripped,
    so log output stays focused on the actual error.
    """
    if not process or not process.stderr:
        return None
    try:
        data = await asyncio.wait_for(process.stderr.read(), timeout=2.0)
        if not data:
            return None
        return _summarize_ffmpeg_stderr(data.decode(errors="replace")) or None
    except (TimeoutError, Exception):
        return None


# Max consecutive RTSP reconnections before giving up.
# Some printer firmwares (notably P2S) drop RTSP sessions after a few seconds,
# so we transparently respawn ffmpeg to keep the MJPEG stream alive.
_RTSP_MAX_RECONNECTS = 30
_RTSP_RECONNECT_DELAY = 0.2  # seconds between respawns


async def generate_rtsp_mjpeg_stream(
    ip_address: str,
    access_code: str,
    model: str | None,
    fps: int = 10,
    stream_id: str | None = None,
    disconnect_event: asyncio.Event | None = None,
    printer_id: int | None = None,
) -> AsyncGenerator[bytes, None]:
    """Generate MJPEG stream from printer camera using ffmpeg/RTSP.

    This is for X1/H2/P2 models that support RTSP streaming.
    Auto-reconnects when the printer drops the RTSP session (common on P2S).
    """
    ffmpeg = get_ffmpeg_path()
    if not ffmpeg:
        logger.error("ffmpeg not found - camera streaming requires ffmpeg")
        yield (b"--frame\r\nContent-Type: text/plain\r\n\r\nError: ffmpeg not installed\r\n")
        return

    port = get_camera_port(model)

    # Use a local TLS proxy so Python's OpenSSL handles TLS instead of
    # ffmpeg's GnuTLS.  This fixes P2S (and potentially other models)
    # dropping the RTSP session after a few seconds due to GnuTLS's
    # hardened Debian defaults rejecting TLS renegotiation.
    proxy_port, proxy_server = await create_tls_proxy(ip_address, port)
    camera_url = f"rtsp://bblp:{access_code}@127.0.0.1:{proxy_port}/streaming/live/1"

    # ffmpeg command to output MJPEG stream to stdout
    cmd = [
        ffmpeg,
        "-rtsp_transport",
        "tcp",
        "-rtsp_flags",
        "prefer_tcp",
        "-timeout",
        "30000000",  # 30 seconds in microseconds
        "-buffer_size",
        "1024000",  # 1MB buffer
        "-max_delay",
        "500000",  # 0.5 seconds max delay
        "-probesize",
        "32",  # Minimal probing for faster startup
        "-analyzeduration",
        "0",  # Skip format analysis for faster startup
        "-fflags",
        "nobuffer",  # Reduce internal buffering
        "-flags",
        "low_delay",  # Minimize decode latency
        "-i",
        camera_url,
        "-f",
        "mjpeg",
        "-q:v",
        "5",
        "-r",
        str(fps),
        "-an",  # No audio
        "-",  # Output to stdout
    ]

    # Register disconnect event so stop endpoint can signal us
    if stream_id and disconnect_event:
        _disconnect_events[stream_id] = disconnect_event

    logger.info(
        "Starting RTSP camera stream for %s (stream_id=%s, model=%s, fps=%s)", ip_address, stream_id, model, fps
    )
    logger.debug("ffmpeg command: %s ... (url hidden)", ffmpeg)

    # On Windows, spawn ffmpeg in its own process group so that
    # terminate() doesn't broadcast CTRL_C_EVENT to uvicorn (#605).
    spawn_kwargs: dict = {}
    if sys.platform == "win32":
        spawn_kwargs["creationflags"] = subprocess.CREATE_NEW_PROCESS_GROUP

    jpeg_start = b"\xff\xd8"
    jpeg_end = b"\xff\xd9"
    reconnect_count = 0
    process = None
    got_any_frames = False

    try:
        while reconnect_count <= _RTSP_MAX_RECONNECTS:
            # Check for client disconnect before (re)connecting
            if disconnect_event and disconnect_event.is_set():
                break

            if reconnect_count > 0:
                logger.info(
                    "RTSP reconnecting (%d/%d) for %s (stream_id=%s)",
                    reconnect_count,
                    _RTSP_MAX_RECONNECTS,
                    ip_address,
                    stream_id,
                )
                await asyncio.sleep(_RTSP_RECONNECT_DELAY)
                if disconnect_event and disconnect_event.is_set():
                    break

            # Spawn ffmpeg
            process = await asyncio.create_subprocess_exec(
                *cmd,
                stdout=asyncio.subprocess.PIPE,
                stderr=asyncio.subprocess.PIPE,
                **spawn_kwargs,
            )

            if stream_id:
                _active_streams[stream_id] = process
            import time as _time

            _spawned_ffmpeg_pids[process.pid] = _time.time()

            # Brief check for immediate startup failures
            await asyncio.sleep(0.1)
            if process.returncode is not None:
                stderr = await process.stderr.read()
                stderr_text = _summarize_ffmpeg_stderr(stderr.decode(errors="replace"))
                logger.error("ffmpeg failed immediately (attempt %d): %s", reconnect_count + 1, stderr_text)
                _spawned_ffmpeg_pids.pop(process.pid, None)
                if not got_any_frames and reconnect_count == 0:
                    # First attempt failed immediately — camera is likely unreachable
                    yield (
                        b"--frame\r\n"
                        b"Content-Type: text/plain\r\n\r\n"
                        b"Error: Camera connection failed. Check printer is on and camera is enabled.\r\n"
                    )
                    return
                reconnect_count += 1
                continue

            # Read JPEG frames from ffmpeg stdout
            buffer = b""
            stream_ended = False
            client_gone = False

            while True:
                if disconnect_event and disconnect_event.is_set():
                    client_gone = True
                    break

                try:
                    chunk = await asyncio.wait_for(process.stdout.read(8192), timeout=30.0)

                    if not chunk:
                        # ffmpeg exited — log stderr and break to reconnect
                        stderr_text = await _read_ffmpeg_stderr(process)
                        if stderr_text:
                            logger.warning("ffmpeg stderr (stream_id=%s): %s", stream_id, stderr_text)
                        logger.warning("RTSP stream ended for %s (stream_id=%s), will reconnect", ip_address, stream_id)
                        stream_ended = True
                        break

                    buffer += chunk

                    # Extract complete JPEG frames from buffer
                    while True:
                        start_idx = buffer.find(jpeg_start)
                        if start_idx == -1:
                            buffer = buffer[-2:] if len(buffer) > 2 else buffer
                            break

                        if start_idx > 0:
                            buffer = buffer[start_idx:]

                        end_idx = buffer.find(jpeg_end, 2)
                        if end_idx == -1:
                            break

                        frame = buffer[: end_idx + 2]
                        buffer = buffer[end_idx + 2 :]
                        got_any_frames = True

                        if printer_id is not None:
                            import time

                            _last_frames[printer_id] = frame
                            _last_frame_times[printer_id] = time.time()
                            if stream_id:
                                _stream_last_frame_times[stream_id] = time.time()

                        yield (
                            b"--frame\r\n"
                            b"Content-Type: image/jpeg\r\n"
                            b"Content-Length: " + str(len(frame)).encode() + b"\r\n"
                            b"\r\n" + frame + b"\r\n"
                        )

                except TimeoutError:
                    stderr_text = await _read_ffmpeg_stderr(process)
                    if stderr_text:
                        logger.warning("ffmpeg stderr on timeout: %s", stderr_text)
                    logger.warning("RTSP read timeout for %s (stream_id=%s)", ip_address, stream_id)
                    stream_ended = True
                    break
                except asyncio.CancelledError:
                    logger.info("Camera stream cancelled (stream_id=%s)", stream_id)
                    client_gone = True
                    break
                except GeneratorExit:
                    logger.info("Camera stream generator exit (stream_id=%s)", stream_id)
                    client_gone = True
                    break

            # Clean up this ffmpeg process before reconnecting or exiting
            await _terminate_ffmpeg(process, stream_id)
            process = None

            if client_gone:
                break

            # Check if stream was explicitly stopped (e.g., by stop endpoint)
            if stream_id and stream_id not in _active_streams:
                logger.info("Stream %s removed from active streams, stopping reconnect", stream_id)
                break

            if stream_ended:
                reconnect_count += 1
                continue

            # Normal exit (shouldn't reach here, but be safe)
            break

        if reconnect_count > _RTSP_MAX_RECONNECTS:
            logger.error(
                "RTSP max reconnects (%d) reached for %s (stream_id=%s)",
                _RTSP_MAX_RECONNECTS,
                ip_address,
                stream_id,
            )

    except FileNotFoundError:
        logger.error("ffmpeg not found - camera streaming requires ffmpeg")
        yield (b"--frame\r\nContent-Type: text/plain\r\n\r\nError: ffmpeg not installed\r\n")
    except asyncio.CancelledError:
        logger.info("Camera stream task cancelled (stream_id=%s)", stream_id)
    except GeneratorExit:
        logger.info("Camera stream generator closed (stream_id=%s)", stream_id)
    except Exception as e:
        logger.exception("Camera stream error: %s", e)
    finally:
        # Remove from active streams and disconnect events
        if stream_id:
            _active_streams.pop(stream_id, None)
            _disconnect_events.pop(stream_id, None)
            _stream_last_frame_times.pop(stream_id, None)

        # Clean up frame buffer and timestamps
        if printer_id is not None:
            _last_frames.pop(printer_id, None)
            _last_frame_times.pop(printer_id, None)
            _stream_start_times.pop(printer_id, None)

        if process:
            await _terminate_ffmpeg(process, stream_id)
            logger.info("Camera stream stopped for %s (stream_id=%s)", ip_address, stream_id)

        # Shut down the TLS proxy
        proxy_server.close()
        await proxy_server.wait_closed()


@router.post("/camera/stream-token")
async def create_stream_token(
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Create a reusable token for camera stream/snapshot access.

    Returns a token valid for 60 minutes that can be appended as ?token=xxx
    to camera stream/snapshot URLs loaded via <img> tags.
    """
    return {"token": await create_camera_stream_token()}


@router.get("/{printer_id}/camera/stream")
async def camera_stream(
    printer_id: int,
    request: Request,
    fps: int = 10,
    db: AsyncSession = Depends(get_db),
    _: None = RequireCameraStreamTokenIfAuthEnabled,
):
    """Stream live video from printer camera as MJPEG.

    This endpoint returns a multipart MJPEG stream that can be used directly
    in an <img> tag or video player.

    Requires a stream token query param (?token=xxx) when auth is enabled.

    Uses external camera if configured, otherwise uses built-in camera:
    - External: MJPEG, RTSP, or HTTP snapshot
    - A1/P1: Chamber image protocol (port 6000)
    - X1/H2/P2: RTSP via ffmpeg (port 322)

    Args:
        printer_id: Printer ID
        fps: Target frames per second (default: 10, max: 30)
    """
    printer = await get_printer_or_404(printer_id, db)

    # Check for external camera first
    if printer.external_camera_enabled and printer.external_camera_url:
        import time

        from backend.app.services.external_camera import generate_mjpeg_stream

        # Limit external camera FPS to reduce browser load
        fps = min(max(fps, 1), 15)
        logger.info(
            "Using external camera (%s) for printer %s at %s fps", printer.external_camera_type, printer_id, fps
        )

        # Track stream start
        _stream_start_times[printer_id] = time.time()
        _active_external_streams.add(printer_id)

        async def external_stream_wrapper():
            """Wrap external stream to track start/stop and update frame times."""
            try:
                async for frame in generate_mjpeg_stream(
                    printer.external_camera_url, printer.external_camera_type, fps
                ):
                    # generate_mjpeg_stream already handles rate limiting;
                    # just track frame times for stall detection
                    _last_frame_times[printer_id] = time.time()
                    yield frame
            finally:
                _active_external_streams.discard(printer_id)
                logger.info("External camera stream ended for printer %s", printer_id)

        return StreamingResponse(
            external_stream_wrapper(),
            media_type="multipart/x-mixed-replace; boundary=frame",
            headers={
                "Cache-Control": "no-cache, no-store, must-revalidate",
                "Pragma": "no-cache",
                "Expires": "0",
            },
        )

    # Validate FPS - A1/P1 models max out at ~5 FPS
    if is_chamber_image_model(printer.model):
        fps = min(max(fps, 1), 5)
    else:
        fps = min(max(fps, 1), 30)

    # Choose the appropriate stream generator based on model
    if is_chamber_image_model(printer.model):
        stream_generator = generate_chamber_mjpeg_stream
        logger.info("Using chamber image protocol for %s", printer.model)
    else:
        stream_generator = generate_rtsp_mjpeg_stream
        logger.info("Using RTSP protocol for %s", printer.model)

    # Track stream start time. Set only if absent so the value reflects when
    # the SHARED upstream first started streaming, not when each new viewer
    # attached — otherwise /camera/status would report stream_uptime jumping
    # backward whenever a second viewer joins. The upstream generator's
    # finally clears this entry when the upstream actually ends.
    import time

    _stream_start_times.setdefault(printer_id, time.time())

    # Fan-out broadcaster (#1089): one upstream connection per printer, shared
    # across all viewers. Most Bambu printers only allow a single concurrent
    # camera connection, so opening the same printer in two tabs would
    # otherwise kick the first viewer off. The broadcaster owns the single
    # upstream and the per-viewer disconnect handling.
    #
    # Note: the upstream's fps is fixed by the first viewer who creates the
    # broadcaster. Concurrent viewers share that rate; new viewers after
    # teardown create a fresh broadcaster at their requested fps.
    fanout_key = f"printer-{printer_id}"
    upstream_stream_id = f"{printer_id}-fanout"

    def _factory(disconnect_event: asyncio.Event):
        # Re-bind locals into the closure so the async generator below sees
        # them — disconnect_event is owned by the broadcaster and signalled
        # when the last subscriber leaves (after the grace window).
        return stream_generator(
            ip_address=printer.ip_address,
            access_code=printer.access_code,
            model=printer.model,
            fps=fps,
            stream_id=upstream_stream_id,
            disconnect_event=disconnect_event,
            printer_id=printer_id,
        )

    # Subscribe with a one-shot retry to close a tiny race: the grace-window
    # teardown can flip the broadcaster to `stopped=True` between the registry
    # lookup and our subscribe call. The retry forces the registry to mint a
    # fresh broadcaster (since the now-stopped one is replaced), and the second
    # subscribe is guaranteed to land on it before any teardown can fire.
    broadcaster: MjpegBroadcaster = await get_or_create_broadcaster(fanout_key, _factory)
    try:
        queue = await broadcaster.subscribe()
    except RuntimeError:
        broadcaster = await get_or_create_broadcaster(fanout_key, _factory)
        queue = await broadcaster.subscribe()
    logger.info(
        "Camera viewer attached to %s (subscribers=%d)",
        fanout_key,
        broadcaster.subscriber_count,
    )

    async def _is_disconnected() -> bool:
        try:
            return await request.is_disconnected()
        except Exception:
            # Older starlette/uvicorn can raise during teardown — treat that
            # as "client gone" so the subscriber cleanly unsubscribes.
            return True

    def _log_detach(remaining: int) -> None:
        logger.info("Camera viewer detached from %s (subscribers=%d)", fanout_key, remaining)

    async def _generate():
        async for chunk in iter_subscriber(
            broadcaster,
            queue,
            is_disconnected=_is_disconnected,
            on_unsubscribe=_log_detach,
        ):
            yield chunk

    return StreamingResponse(
        _generate(),
        media_type="multipart/x-mixed-replace; boundary=frame",
        headers={
            "Cache-Control": "no-cache, no-store, must-revalidate",
            "Pragma": "no-cache",
            "Expires": "0",
        },
    )


@router.api_route("/{printer_id}/camera/stop", methods=["GET", "POST"])
async def stop_camera_stream(
    printer_id: int,
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Stop all active camera streams for a printer.

    This can be called by the frontend when the camera window is closed.
    Accepts both GET and POST (POST for sendBeacon compatibility).
    """
    stopped = 0

    # Tear down the fan-out broadcaster first (#1089). This cleanly notifies
    # all subscribed viewers and asks the upstream generator to stop
    # reconnecting before we fall back to forcefully killing the process below.
    if await shutdown_broadcaster(f"printer-{printer_id}"):
        logger.info("Shut down camera fan-out broadcaster for printer %s", printer_id)

    # Stop ffmpeg/RTSP streams
    to_remove = []
    for stream_id, process in list(_active_streams.items()):
        if stream_id.startswith(f"{printer_id}-"):
            to_remove.append(stream_id)
            # Signal the generator to stop reconnecting BEFORE killing the process
            event = _disconnect_events.get(stream_id)
            if event:
                event.set()
            if process.returncode is None:
                try:
                    process.terminate()
                    try:
                        await asyncio.wait_for(process.wait(), timeout=2.0)
                    except TimeoutError:
                        logger.warning("ffmpeg didn't terminate gracefully, killing (stream_id=%s)", stream_id)
                        process.kill()
                        await process.wait()
                    stopped += 1
                    logger.info("Terminated ffmpeg process for stream %s", stream_id)
                except ProcessLookupError:
                    pass  # Process already dead
                except OSError as e:
                    logger.warning("Error stopping stream %s: %s", stream_id, e)
            _spawned_ffmpeg_pids.pop(process.pid, None)

    for stream_id in to_remove:
        _active_streams.pop(stream_id, None)
        _disconnect_events.pop(stream_id, None)
        _stream_last_frame_times.pop(stream_id, None)

    # Stop chamber image streams
    to_remove_chamber = []
    for stream_id, (_reader, writer) in list(_active_chamber_streams.items()):
        if stream_id.startswith(f"{printer_id}-"):
            to_remove_chamber.append(stream_id)
            # Signal the generator to stop
            event = _disconnect_events.get(stream_id)
            if event:
                event.set()
            try:
                writer.close()
                stopped += 1
                logger.info("Closed chamber image connection for stream %s", stream_id)
            except OSError as e:
                logger.warning("Error stopping chamber stream %s: %s", stream_id, e)

    for stream_id in to_remove_chamber:
        _active_chamber_streams.pop(stream_id, None)
        _disconnect_events.pop(stream_id, None)
        _stream_last_frame_times.pop(stream_id, None)

    logger.info("Stopped %s camera stream(s) for printer %s", stopped, printer_id)
    return {"stopped": stopped}


@router.get("/{printer_id}/camera/snapshot")
async def camera_snapshot(
    printer_id: int,
    db: AsyncSession = Depends(get_db),
    _: None = RequireCameraStreamTokenIfAuthEnabled,
):
    """Capture a single frame from the printer camera.

    Returns a JPEG image.

    Requires a stream token query param (?token=xxx) when auth is enabled.
    """
    import tempfile
    from pathlib import Path

    printer = await get_printer_or_404(printer_id, db)

    # Check for external camera first
    if printer.external_camera_enabled and printer.external_camera_url:
        from backend.app.services.external_camera import capture_frame

        frame_data = await capture_frame(
            printer.external_camera_url,
            printer.external_camera_type,
            timeout=15,
            snapshot_url=printer.external_camera_snapshot_url,
        )
        if not frame_data:
            raise HTTPException(
                status_code=503,
                detail="Failed to capture frame from external camera.",
            )
        return Response(
            content=frame_data,
            media_type="image/jpeg",
            headers={
                "Cache-Control": "no-cache, no-store, must-revalidate",
                "Content-Disposition": f'inline; filename="snapshot_{printer_id}.jpg"',
            },
        )

    # Create temporary file for the snapshot (0600 so only the app user can read it)
    fd, tmp_name = tempfile.mkstemp(suffix=".jpg")
    os.close(fd)
    temp_path = Path(tmp_name)
    temp_path.chmod(0o600)

    try:
        success = await capture_camera_frame(
            ip_address=printer.ip_address,
            access_code=printer.access_code,
            model=printer.model,
            output_path=temp_path,
            timeout=15,
        )

        if not success:
            raise HTTPException(
                status_code=503,
                detail="Failed to capture camera frame. Ensure printer is on and camera is enabled.",
            )

        # Read and return the image
        with open(temp_path, "rb") as f:
            image_data = f.read()

        return Response(
            content=image_data,
            media_type="image/jpeg",
            headers={
                "Cache-Control": "no-cache, no-store, must-revalidate",
                "Content-Disposition": f'inline; filename="snapshot_{printer_id}.jpg"',
            },
        )
    finally:
        # Clean up temp file
        if temp_path.exists():
            temp_path.unlink()


@router.get("/{printer_id}/camera/test")
async def test_camera(
    printer_id: int,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Test camera connection for a printer.

    Returns success status and any error message.
    """
    printer = await get_printer_or_404(printer_id, db)

    result = await test_camera_connection(
        ip_address=printer.ip_address,
        access_code=printer.access_code,
        model=printer.model,
    )

    return result


@router.get("/{printer_id}/camera/status")
async def camera_status(
    printer_id: int,
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Get the status of an active camera stream.

    Returns whether a stream is active and when the last frame was received.
    Used by the frontend to detect stalled streams and auto-reconnect.
    """
    import time

    # Check if there's an active stream for this printer
    has_active_stream = False

    # Check external camera streams
    if printer_id in _active_external_streams:
        has_active_stream = True

    # Check ffmpeg/RTSP streams
    if not has_active_stream:
        for stream_id in _active_streams:
            if stream_id.startswith(f"{printer_id}-"):
                process = _active_streams[stream_id]
                if process.returncode is None:
                    has_active_stream = True
                    break

    # Check chamber image streams
    if not has_active_stream:
        for stream_id in _active_chamber_streams:
            if stream_id.startswith(f"{printer_id}-"):
                has_active_stream = True
                break

    # Get timing information
    current_time = time.time()
    last_frame_time = _last_frame_times.get(printer_id)
    stream_start_time = _stream_start_times.get(printer_id)

    # Calculate seconds since last frame
    seconds_since_frame = None
    if last_frame_time is not None:
        seconds_since_frame = current_time - last_frame_time

    # Calculate stream uptime
    stream_uptime = None
    if stream_start_time is not None:
        stream_uptime = current_time - stream_start_time

    return {
        "active": has_active_stream,
        "has_frames": printer_id in _last_frames,
        "seconds_since_frame": seconds_since_frame,
        "stream_uptime": stream_uptime,
        # Consider stalled if no frame for more than 10 seconds after stream started
        "stalled": (
            has_active_stream
            and stream_uptime is not None
            and stream_uptime > 5  # Give 5 seconds for stream to start
            and (seconds_since_frame is None or seconds_since_frame > 10)
        ),
    }


@router.post("/{printer_id}/camera/external/test")
async def test_external_camera(
    printer_id: int,
    url: str,
    camera_type: str,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Test external camera connection.

    Args:
        printer_id: Printer ID (for authorization)
        url: Camera URL or USB device path to test
        camera_type: Camera type ("mjpeg", "rtsp", "snapshot", "usb")

    Returns:
        Dict with {success: bool, error?: str, resolution?: str}
    """
    # Verify printer exists (for authorization)
    await get_printer_or_404(printer_id, db)

    from backend.app.services.external_camera import test_connection

    return await test_connection(url, camera_type)


@router.get("/{printer_id}/camera/check-plate")
async def check_plate_empty(
    printer_id: int,
    plate_type: str | None = None,
    use_external: bool = False,
    include_debug_image: bool = False,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Check if the build plate is empty using camera vision.

    Uses calibration-based difference detection - compares current frame
    to a reference image of the empty plate.

    IMPORTANT: Chamber light must be ON for reliable detection.

    Args:
        printer_id: Printer ID
        plate_type: Type of build plate (e.g., "High Temp Plate") for calibration lookup
        use_external: If True, prefer external camera over built-in
        include_debug_image: If True, return URL to annotated debug image

    Returns:
        Dict with detection results:
        - is_empty: bool - Whether plate appears empty
        - confidence: float - Confidence level (0.0 to 1.0)
        - difference_percent: float - How different from calibration reference
        - message: str - Human-readable result message
        - needs_calibration: bool - True if calibration is required
        - light_warning: bool - True if chamber light is off
    """
    from backend.app.services.plate_detection import (
        check_plate_empty as do_check,
        is_plate_detection_available,
    )
    from backend.app.services.printer_manager import printer_manager

    # Check printer exists first (before OpenCV check)
    printer = await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        raise HTTPException(
            status_code=503,
            detail="Plate detection not available. Install opencv-python-headless to enable.",
        )

    # Check chamber light status
    light_warning = False
    state = printer_manager.get_status(printer_id)
    if state and not state.chamber_light:
        light_warning = True

    from backend.app.services.plate_detection import PlateDetector

    # Build ROI tuple from printer settings if available
    roi = None
    if all(
        [
            printer.plate_detection_roi_x is not None,
            printer.plate_detection_roi_y is not None,
            printer.plate_detection_roi_w is not None,
            printer.plate_detection_roi_h is not None,
        ]
    ):
        roi = (
            printer.plate_detection_roi_x,
            printer.plate_detection_roi_y,
            printer.plate_detection_roi_w,
            printer.plate_detection_roi_h,
        )

    result = await do_check(
        printer_id=printer.id,
        ip_address=printer.ip_address,
        access_code=printer.access_code,
        model=printer.model,
        plate_type=plate_type,
        include_debug_image=include_debug_image,
        external_camera_url=printer.external_camera_url if printer.external_camera_enabled else None,
        external_camera_type=printer.external_camera_type if printer.external_camera_enabled else None,
        use_external=use_external,
        roi=roi,
        external_camera_snapshot_url=printer.external_camera_snapshot_url if printer.external_camera_enabled else None,
    )

    # Get reference count for the response
    detector = PlateDetector()
    ref_count = detector.get_calibration_count(printer.id)

    response = result.to_dict()
    response["light_warning"] = light_warning
    response["reference_count"] = ref_count
    response["max_references"] = detector.MAX_REFERENCES
    # Include current ROI in response
    if roi:
        response["roi"] = {"x": roi[0], "y": roi[1], "w": roi[2], "h": roi[3]}
    else:
        # Return default ROI
        response["roi"] = {"x": 0.15, "y": 0.35, "w": 0.70, "h": 0.55}

    # If debug image requested and available, encode as base64 data URL
    if include_debug_image and result.debug_image:
        import base64

        b64_image = base64.b64encode(result.debug_image).decode("utf-8")
        response["debug_image_url"] = f"data:image/jpeg;base64,{b64_image}"

    return response


@router.post("/{printer_id}/camera/plate-detection/calibrate")
async def calibrate_plate_detection(
    printer_id: int,
    label: str | None = None,
    use_external: bool = False,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Calibrate plate detection by capturing a reference image of the empty plate.

    The plate MUST be empty when calling this endpoint. The captured image
    will be used as the reference for future detection comparisons.

    Supports up to 5 reference images per printer. When adding a 6th, the oldest
    is automatically removed.

    IMPORTANT: Chamber light should be ON for calibration.

    Args:
        printer_id: Printer ID
        label: Optional label for this reference (e.g., "High Temp Plate", "Wham Bam")
        use_external: If True, prefer external camera over built-in

    Returns:
        Dict with:
        - success: bool - Whether calibration succeeded
        - message: str - Status message
        - index: int - The reference slot used (0-4)
    """
    from backend.app.services.plate_detection import (
        calibrate_plate,
        is_plate_detection_available,
    )
    from backend.app.services.printer_manager import printer_manager

    # Check printer exists first (before OpenCV check)
    printer = await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        raise HTTPException(
            status_code=503,
            detail="Plate detection not available. Install opencv-python-headless to enable.",
        )

    # Check chamber light - warn but don't block
    state = printer_manager.get_status(printer_id)
    light_warning = state and not state.chamber_light

    success, message, index = await calibrate_plate(
        printer_id=printer.id,
        ip_address=printer.ip_address,
        access_code=printer.access_code,
        model=printer.model,
        label=label,
        external_camera_url=printer.external_camera_url if printer.external_camera_enabled else None,
        external_camera_type=printer.external_camera_type if printer.external_camera_enabled else None,
        use_external=use_external,
        external_camera_snapshot_url=printer.external_camera_snapshot_url if printer.external_camera_enabled else None,
    )

    if light_warning and success:
        message += " (Warning: Chamber light was off)"

    return {"success": success, "message": message, "index": index}


@router.delete("/{printer_id}/camera/plate-detection/calibrate")
async def delete_plate_calibration(
    printer_id: int,
    plate_type: str | None = None,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Delete the plate detection calibration for a printer and plate type.

    Args:
        printer_id: Printer ID
        plate_type: Type of build plate (if None, deletes legacy non-plate-specific calibration)

    Returns:
        Dict with:
        - success: bool - Whether deletion succeeded
        - message: str - Status message
    """
    from backend.app.services.plate_detection import (
        delete_calibration,
        is_plate_detection_available,
    )

    # Verify printer exists first (before OpenCV check)
    await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        raise HTTPException(
            status_code=503,
            detail="Plate detection not available. Install opencv-python-headless to enable.",
        )

    deleted = delete_calibration(printer_id, plate_type)
    plate_msg = f" for '{plate_type}'" if plate_type else ""

    return {
        "success": deleted,
        "message": f"Calibration deleted{plate_msg}" if deleted else f"No calibration found{plate_msg}",
    }


@router.get("/{printer_id}/camera/plate-detection/status")
async def get_plate_detection_status(
    printer_id: int,
    plate_type: str | None = None,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Check plate detection status for a printer and plate type.

    Returns:
        Dict with:
        - available: bool - Whether OpenCV is installed
        - calibrated: bool - Whether printer has calibration for this plate type
        - plate_type: str - The plate type queried
        - chamber_light: bool - Whether chamber light is on
        - message: str - Status message
    """
    from backend.app.services.plate_detection import (
        get_calibration_status,
        is_plate_detection_available,
    )
    from backend.app.services.printer_manager import printer_manager

    # Verify printer exists first (before OpenCV check)
    await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        return {
            "available": False,
            "calibrated": False,
            "plate_type": plate_type,
            "chamber_light": False,
            "message": "OpenCV not installed",
        }

    # Get chamber light status
    state = printer_manager.get_status(printer_id)
    chamber_light = state.chamber_light if state else False

    status = get_calibration_status(printer_id, plate_type)
    status["chamber_light"] = chamber_light

    return status


@router.get("/{printer_id}/camera/plate-detection/references")
async def get_plate_references(
    printer_id: int,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Get all calibration references for a printer with metadata.

    Returns list of references with index, label, timestamp, and thumbnail URL.
    """
    from backend.app.services.plate_detection import PlateDetector, is_plate_detection_available

    # Verify printer exists first (before OpenCV check)
    await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        raise HTTPException(503, "Plate detection not available")

    detector = PlateDetector()
    references = detector.get_references(printer_id)

    # Add thumbnail URLs
    for ref in references:
        ref["thumbnail_url"] = (
            f"/api/v1/printers/{printer_id}/camera/plate-detection/references/{ref['index']}/thumbnail"
        )

    return {
        "references": references,
        "max_references": detector.MAX_REFERENCES,
    }


@router.get("/{printer_id}/camera/plate-detection/references/{index}/thumbnail")
async def get_reference_thumbnail(
    printer_id: int,
    index: int,
    db: AsyncSession = Depends(get_db),
    _: None = RequireCameraStreamTokenIfAuthEnabled,
):
    """Get thumbnail image for a calibration reference.

    Requires a stream token query param (?token=xxx) when auth is enabled.
    """
    from fastapi.responses import Response

    from backend.app.services.plate_detection import PlateDetector, is_plate_detection_available

    # Verify printer exists first (before OpenCV check)
    await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        raise HTTPException(503, "Plate detection not available")

    detector = PlateDetector()
    thumbnail = detector.get_reference_thumbnail(printer_id, index)

    if thumbnail is None:
        raise HTTPException(404, "Reference not found")

    return Response(content=thumbnail, media_type="image/jpeg")


@router.put("/{printer_id}/camera/plate-detection/references/{index}")
async def update_reference_label(
    printer_id: int,
    index: int,
    label: str,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Update the label for a calibration reference."""
    from backend.app.services.plate_detection import PlateDetector, is_plate_detection_available

    # Verify printer exists first (before OpenCV check)
    await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        raise HTTPException(503, "Plate detection not available")

    detector = PlateDetector()
    success = detector.update_reference_label(printer_id, index, label)

    if not success:
        raise HTTPException(404, "Reference not found")

    return {"success": True, "index": index, "label": label}


@router.delete("/{printer_id}/camera/plate-detection/references/{index}")
async def delete_reference(
    printer_id: int,
    index: int,
    db: AsyncSession = Depends(get_db),
    _: User | None = RequirePermissionIfAuthEnabled(Permission.CAMERA_VIEW),
):
    """Delete a specific calibration reference."""
    from backend.app.services.plate_detection import PlateDetector, is_plate_detection_available

    # Verify printer exists first (before OpenCV check)
    await get_printer_or_404(printer_id, db)

    if not is_plate_detection_available():
        raise HTTPException(503, "Plate detection not available")

    detector = PlateDetector()
    success = detector.delete_reference(printer_id, index)

    if not success:
        raise HTTPException(404, "Reference not found")

    return {"success": True, "message": "Reference deleted"}


def _scan_bambu_ffmpeg_pids() -> list[int]:
    """Scan /proc for ffmpeg processes with Bambu RTSP URLs.

    These are definitely ours — no other software connects to rtsp(s)://bblp:.
    This catches orphans that survive app restarts and are not in any tracking dict.
    """
    import os

    pids = []
    try:
        for entry in os.listdir("/proc"):
            if not entry.isdigit():
                continue
            try:
                with open(f"/proc/{entry}/cmdline", "rb") as f:
                    cmdline = f.read()
                # Match both rtsp:// (via TLS proxy) and rtsps:// (direct)
                if b"ffmpeg" in cmdline and (b"rtsp://bblp:" in cmdline or b"rtsps://bblp:" in cmdline):
                    pids.append(int(entry))
            except (OSError, PermissionError, ValueError):
                continue
    except OSError:
        pass
    return pids


async def cleanup_orphaned_streams():
    """Clean up orphaned ffmpeg processes and stale stream entries.

    Called periodically from the background task loop in main.py.

    Three-layer cleanup:
    1. /proc scan — finds ALL Bambu ffmpeg processes on the system, even those
       from previous app sessions. This is the nuclear safety net.
    2. _spawned_ffmpeg_pids — tracks PIDs spawned this session, catches orphans
       that were removed from _active_streams but not killed.
    3. _active_streams — kills stale entries with no recent frames.
    """
    import os
    import signal
    import time

    cleaned = 0
    now = time.time()

    # Collect PIDs that are legitimately in-use (active stream, process alive)
    active_pids = {proc.pid for proc in _active_streams.values() if proc.returncode is None}

    # Also exclude PIDs from one-shot snapshot captures (Obico detection, finish photos, etc.)
    from backend.app.services.camera import _active_capture_pids

    active_pids |= _active_capture_pids

    # 1. /proc scan — catch ALL orphaned Bambu ffmpeg processes on the system.
    #    Any ffmpeg with rtsp(s)://bblp: that is NOT in an active stream is orphaned.
    for pid in _scan_bambu_ffmpeg_pids():
        if pid in active_pids:
            continue
        logger.info("Killing orphaned ffmpeg process found via /proc (pid=%d)", pid)
        try:
            os.kill(pid, signal.SIGKILL)
        except (ProcessLookupError, OSError):
            pass
        _spawned_ffmpeg_pids.pop(pid, None)
        cleaned += 1

    # 2. Clean up _spawned_ffmpeg_pids entries for dead processes
    for pid in list(_spawned_ffmpeg_pids):
        try:
            os.kill(pid, 0)  # existence check
        except (ProcessLookupError, OSError):
            _spawned_ffmpeg_pids.pop(pid, None)

    # 3. Clean up _active_streams entries with dead processes
    dead_streams = [sid for sid, proc in _active_streams.items() if proc.returncode is not None]
    for sid in dead_streams:
        proc = _active_streams.pop(sid, None)
        if proc:
            _spawned_ffmpeg_pids.pop(proc.pid, None)
        cleaned += 1

    # 4. Kill stale active streams (alive but no frames for >30s)
    # Uses per-stream timestamps to avoid false "fresh" readings from newer streams
    for sid, proc in list(_active_streams.items()):
        if proc.returncode is not None:
            continue
        # Per-stream frame time is authoritative; fall back to per-printer
        stream_last_frame = _stream_last_frame_times.get(sid)
        if stream_last_frame is None:
            try:
                printer_id = int(sid.split("-", 1)[0])
            except (ValueError, IndexError):
                continue
            stream_last_frame = _last_frame_times.get(printer_id)
        spawn_time = _spawned_ffmpeg_pids.get(proc.pid, now)
        if stream_last_frame is None:
            stream_last_frame = spawn_time
        if now - spawn_time > 60 and now - stream_last_frame > 30:
            logger.info("Killing stale ffmpeg stream %s (no frames for %.0fs)", sid, now - stream_last_frame)
            # Signal the generator to stop reconnecting
            event = _disconnect_events.get(sid)
            if event:
                event.set()
            try:
                proc.kill()
                await proc.wait()
            except (ProcessLookupError, OSError):
                pass
            _active_streams.pop(sid, None)
            _disconnect_events.pop(sid, None)
            _stream_last_frame_times.pop(sid, None)
            _spawned_ffmpeg_pids.pop(proc.pid, None)
            cleaned += 1

    # 4. Clean stale chamber stream entries
    dead_chamber = [sid for sid, (_reader, writer) in _active_chamber_streams.items() if writer.is_closing()]
    for sid in dead_chamber:
        _active_chamber_streams.pop(sid, None)
        cleaned += 1

    if cleaned:
        logger.info("Cleaned up %d orphaned camera stream(s)", cleaned)