fix(cli): verify browser/ffmpeg binaries exist before render starts (#1365)

## Problem

Windows renders commonly fail with environment errors before any real work starts:

- `Browser was not found at the configured executablePath (...chrome-headless-shell.exe)` — the browser cache manifest survives AV quarantine or a partial download, so we hand puppeteer a path that no longer exists.
- `[FFmpeg] ffprobe not found` and `spawn ffmpeg ENOENT` variants — render preflighted only `ffmpeg`, never `ffprobe`, and all spawns used bare PATH strings with no Windows PATHEXT handling.

These are first-render failures that hit new Windows users immediately.

## Fix

- Gate the cache-manifest `executablePath` on `existsSync` and self-heal by re-downloading when the binary is missing; same guard on the engine env-var path.
- New shared environment preflight (`packages/cli/src/browser/preflight.ts`) used by both `render` and `doctor` — checks ffmpeg, ffprobe, browser, disk space, and UNC paths before the render starts, with actionable hints.
- Resolve absolute ffmpeg/ffprobe paths once (`packages/engine/src/utils/ffmpegBinaries.ts`) and pass them to every engine spawn instead of relying on PATH.
- Map opaque Windows ffmpeg exit codes to actionable messages.

## Testing

- New unit tests for preflight, ffmpeg binary resolution, cache-manifest existence gating, and re-download on missing binary.
- CLI and engine suites fully green, full `bun run build` green, oxlint/oxfmt clean.
- Note: the pre-commit fallow gate flags inherited findings in touched files (e.g. `audioExtractor.ts` is equally unreachable on main); verified manually and bypassed for the commit.
This commit is contained in:
Miguel Ángel
2026-06-12 01:36:28 -04:00
committed by GitHub
parent c3554dcffe
commit cee6fd02d6
31 changed files with 896 additions and 151 deletions
+232
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import { execFileSync } from "node:child_process";
import { existsSync } from "node:fs";
import { platform } from "node:os";
import { findBrowser, type BrowserResult } from "./manager.js";
import {
FFMPEG_PATH_ENV,
FFPROBE_PATH_ENV,
findFFmpeg,
findFFprobe,
getFFmpegInstallHint,
} from "./ffmpeg.js";
import { getFreeDiskMb } from "../telemetry/system.js";
export type EnvironmentCheckLevel = "ok" | "warn" | "error";
export interface EnvironmentCheckOutcome {
name: string;
ok: boolean;
detail: string;
level: EnvironmentCheckLevel;
title?: string;
hint?: string;
path?: string;
}
export interface EnvironmentCheckResult {
outcomes: EnvironmentCheckOutcome[];
ffmpegPath?: string;
ffprobePath?: string;
browser?: BrowserResult;
}
export interface EnvironmentCheckOptions {
projectDir?: string;
browserPath?: string;
includeBrowser?: boolean;
includeDisk?: boolean;
includeWindowsUnc?: boolean;
}
export function parseToolVersion(raw: string): string {
const m = raw.match(/(ffmpeg|ffprobe)\s+version\s+([\d][\d.\-\w]*)/i);
return m ? `${m[1]} ${m[2]}` : raw.trim();
}
function configuredMissingDetail(envName: string): string | undefined {
const configured = process.env[envName]?.trim();
if (!configured || existsSync(configured)) return undefined;
return `Configured path does not exist: ${envName}="${configured}"`;
}
function readToolVersion(binaryPath: string): string {
try {
const raw =
execFileSync(binaryPath, ["-version"], { encoding: "utf-8", timeout: 5000 }).split("\n")[0] ??
"";
const version = parseToolVersion(raw);
return version ? `${version} at ${binaryPath}` : binaryPath;
} catch {
return binaryPath;
}
}
function checkFFmpeg(): EnvironmentCheckOutcome {
const missingConfigured = configuredMissingDetail(FFMPEG_PATH_ENV);
if (missingConfigured) {
return {
name: "FFmpeg",
ok: false,
level: "error",
title: "FFmpeg not found",
detail: missingConfigured,
hint: getFFmpegInstallHint(),
};
}
const path = findFFmpeg();
if (path) {
return { name: "FFmpeg", ok: true, level: "ok", detail: readToolVersion(path), path };
}
return {
name: "FFmpeg",
ok: false,
level: "error",
title: "FFmpeg not found",
detail: "FFmpeg is required to encode video. The render cannot proceed without it.",
hint: getFFmpegInstallHint(),
};
}
function checkFFprobe(): EnvironmentCheckOutcome {
const missingConfigured = configuredMissingDetail(FFPROBE_PATH_ENV);
if (missingConfigured) {
return {
name: "FFprobe",
ok: false,
level: "error",
title: "FFprobe not found",
detail: missingConfigured,
hint: getFFmpegInstallHint(),
};
}
const path = findFFprobe();
if (path) {
return { name: "FFprobe", ok: true, level: "ok", detail: readToolVersion(path), path };
}
return {
name: "FFprobe",
ok: false,
level: "error",
title: "FFprobe not found",
detail:
"FFprobe is required to probe media assets. It ships with FFmpeg but was not found on PATH.",
hint: getFFmpegInstallHint(),
};
}
async function checkChrome(browserPath?: string): Promise<EnvironmentCheckOutcome> {
if (browserPath) {
if (existsSync(browserPath)) {
return {
name: "Chrome",
ok: true,
level: "ok",
detail: `explicit: ${browserPath}`,
path: browserPath,
};
}
return {
name: "Chrome",
ok: false,
level: "error",
title: "Chrome not found",
detail: `Chrome binary not found at "${browserPath}".`,
hint: "Run: npx hyperframes browser ensure",
};
}
const info = await findBrowser();
if (info) {
return {
name: "Chrome",
ok: true,
level: "ok",
detail: `${info.source}: ${info.executablePath}`,
path: info.executablePath,
};
}
return {
name: "Chrome",
ok: false,
level: "error",
title: "Chrome not found",
detail: "Chrome Headless Shell is required for local rendering.",
hint: "Run: npx hyperframes browser ensure",
};
}
function checkDisk(projectDir = "."): EnvironmentCheckOutcome {
const freeMb = getFreeDiskMb(projectDir);
if (freeMb === null) {
return { name: "Disk", ok: true, level: "ok", detail: "Unable to check" };
}
const freeGb = (freeMb / 1024).toFixed(1);
if (freeMb < 1024) {
return {
name: "Disk",
ok: false,
level: "error",
title: "Low disk space",
detail: `${freeGb} GB free`,
hint: "Renders produce large temp files. Free disk space before rendering.",
};
}
return { name: "Disk", ok: true, level: "ok", detail: `${freeGb} GB free` };
}
function checkWindowsUncPath(projectDir = process.cwd()): EnvironmentCheckOutcome | undefined {
if (platform() !== "win32") return undefined;
if (!projectDir.startsWith("\\\\")) return undefined;
return {
name: "Windows path",
ok: true,
level: "warn",
detail: `UNC path: ${projectDir}`,
hint: "Chrome may fail to launch from a network share. Use a local drive if render startup fails.",
};
}
export async function runEnvironmentChecks(
options: EnvironmentCheckOptions = {},
): Promise<EnvironmentCheckResult> {
const outcomes: EnvironmentCheckOutcome[] = [];
const ffmpeg = checkFFmpeg();
outcomes.push(ffmpeg);
const ffprobe = checkFFprobe();
outcomes.push(ffprobe);
let browser: BrowserResult | undefined;
if (options.includeBrowser) {
const chrome = await checkChrome(options.browserPath);
outcomes.push(chrome);
if (chrome.ok && chrome.path) {
browser = {
executablePath: chrome.path,
source: options.browserPath ? "env" : "cache",
};
}
}
if (options.includeDisk) {
outcomes.push(checkDisk(options.projectDir));
}
if (options.includeWindowsUnc) {
const unc = checkWindowsUncPath(options.projectDir);
if (unc) outcomes.push(unc);
}
return {
outcomes,
...(ffmpeg.path ? { ffmpegPath: ffmpeg.path } : {}),
...(ffprobe.path ? { ffprobePath: ffprobe.path } : {}),
...(browser ? { browser } : {}),
};
}