From ee6918445ecdf267402d59d3a46eecf2ae36030d Mon Sep 17 00:00:00 2001
From: Miguel <miguel.vera.csa@gmail.com>
Date: Fri, 22 Aug 2025 14:13:07 +0200
Subject: [PATCH] feat: Implement robust backend instance management with HTTP
 health checks and PID verification

- Added InstanceManager class for managing backend instances.
- Introduced double HTTP health checks with configurable intervals.
- Implemented PID-based verification and cleanup of stale processes.
- Enhanced instance initialization and cleanup processes.
- Updated main.py to utilize the new instance management system.
- Modified system_state.json to reflect changes in active datasets and last update timestamp.
---
 application_events.json   | 5110 ++++++++++++++++---------------------
 main.py                   |  126 +-
 system_state.json         |    6 +-
 utils/instance_manager.py |  283 ++
 4 files changed, 2594 insertions(+), 2931 deletions(-)
 create mode 100644 utils/instance_manager.py

diff --git a/application_events.json b/application_events.json
index 1c9ce6d..223f7e9 100644
--- a/application_events.json
+++ b/application_events.json
@@ -1,2880 +1,5 @@
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+        "read_time_avg": 0.08634228110313416,
+        "csv_write_time_avg": 0.0
+      }
     }
   ],
-  "last_updated": "2025-08-22T12:42:37.908534",
+  "last_updated": "2025-08-22T14:13:03.835010",
   "total_entries": 1000
 }
\ No newline at end of file
diff --git a/main.py b/main.py
index d2f5311..ee042d6 100644
--- a/main.py
+++ b/main.py
@@ -10,6 +10,7 @@ import json
 import time
 import signal
 import sys
+import requests  # For HTTP health checks
 from datetime import datetime, timedelta, timezone
 import os
 import logging
@@ -50,56 +51,53 @@ from core.historical_cache import HistoricalDataCache
 from utils.json_manager import JSONManager, SchemaManager
 from utils.symbol_loader import SymbolLoader
 from utils.symbol_processor import SymbolProcessor
+from utils.instance_manager import InstanceManager
 
 
-def check_for_running_instance_early():
+def check_backend_instance_robust(port: int = 5050, lock_file: str = "plc_streamer.lock"):
     """
-    Optional early check for running instance before initializing PLCDataStreamer.
-    This provides faster feedback to the user without going through full initialization.
+    🔒 ROBUST INSTANCE CHECK - HTTP + PID based verification
+    
+    This function provides a more reliable way to detect existing backend instances:
+    1. Double HTTP health check with 5-second interval
+    2. PID verification and zombie process cleanup
+    3. Automatic lock file management
+    
+    Args:
+        port: Backend server port (default: 5050)
+        lock_file: Lock file path (default: "plc_streamer.lock")
+        
+    Returns:
+        Tuple[bool, str]: (can_proceed, message)
+        - can_proceed: True if this instance can start safely
+        - message: Detailed status message
     """
-    import psutil
-
-    lock_file = "plc_streamer.lock"
-
-    if not os.path.exists(lock_file):
-        return True  # No lock file, safe to proceed
-
+    print("🔍 Starting robust backend instance verification...")
+    
     try:
-        with open(lock_file, "r") as f:
-            old_pid = int(f.read().strip())
-
-        if psutil.pid_exists(old_pid):
-            proc = psutil.Process(old_pid)
-            cmdline = " ".join(proc.cmdline())
-
-            # Check if it's really our application
-            if (
-                ("main.py" in cmdline and "S7_snap7_Stremer_n_Log" in cmdline)
-                or ("plc_streamer" in cmdline.lower())
-                or ("PLCDataStreamer" in cmdline)
-            ):
-                print(f"🚫 Another instance is already running (PID: {old_pid})")
-                print(f"📋 Process: {proc.name()}")
-                print(f"💻 Command: {cmdline}")
-                return False
-
-        # Process not running or different process, remove stale lock
-        os.remove(lock_file)
-        print(f"🧹 Removed stale lock file")
-        return True
-
-    except (ValueError, psutil.NoSuchProcess, psutil.AccessDenied, FileNotFoundError):
-        # Invalid or inaccessible, remove lock file if exists
-        if os.path.exists(lock_file):
-            try:
-                os.remove(lock_file)
-                print(f"🧹 Removed invalid lock file")
-            except:
-                pass
-        return True
+        # Initialize instance manager
+        instance_manager = InstanceManager(port=port, lock_file=lock_file)
+        
+        # Perform comprehensive instance check
+        can_proceed, message = instance_manager.check_and_handle_existing_instance()
+        
+        if can_proceed:
+            print(f"✅ {message}")
+            print("🔒 Initializing new backend instance...")
+            
+            # Create lock file for this instance
+            if not instance_manager.initialize_instance():
+                return False, "❌ Failed to create instance lock file"
+                
+            return True, "✅ Backend instance ready to start"
+        else:
+            print(f"🚫 {message}")
+            return False, message
+            
     except Exception as e:
-        print(f"⚠️ Error checking instance: {e}")
-        return True  # On error, allow to proceed
+        error_msg = f"❌ Error during instance verification: {e}"
+        print(error_msg)
+        return False, error_msg
 
 
 app = Flask(__name__)
@@ -3197,7 +3195,7 @@ def stream_status():
 
 
 def graceful_shutdown():
-    """Perform graceful shutdown"""
+    """Perform graceful shutdown with robust instance cleanup"""
     print("\n⏹️  Performing graceful shutdown...")
     try:
         if streamer is not None:
@@ -3223,6 +3221,26 @@ def graceful_shutdown():
         else:
             print("⚠️ Streamer not initialized, skipping shutdown steps")
 
+        # 🔒 ROBUST CLEANUP: Use instance manager for reliable lock file cleanup
+        print("🧹 Cleaning up instance lock file...")
+        try:
+            instance_manager = InstanceManager(port=5050, lock_file="plc_streamer.lock")
+            if instance_manager.cleanup_instance():
+                print("✅ Instance lock file cleaned up successfully")
+            else:
+                print("⚠️ Warning: Instance lock file cleanup had issues")
+        except Exception as cleanup_error:
+            print(f"⚠️ Error during instance cleanup: {cleanup_error}")
+            # Fallback to direct file removal
+            try:
+                import os
+                lock_file = "plc_streamer.lock"
+                if os.path.exists(lock_file):
+                    os.remove(lock_file)
+                    print(f"🧹 Emergency cleanup: Removed lock file directly")
+            except:
+                pass  # Silent fail for emergency cleanup
+
         print("📝 Closing rotating logger system...")
         # 📝 Close rotating logger system
         backend_logger.close()
@@ -3928,16 +3946,19 @@ if __name__ == "__main__":
     print(f"🚀 Starting PLC S7-315 Streamer & Logger...")
     print(f"🐍 Process PID: {os.getpid()}")
 
-    # 🔍 OPTIONAL: Early check for existing instance (faster feedback)
-    # Comment out the next 4 lines if you prefer the full error handling in PLCDataStreamer
-    if not check_for_running_instance_early():
-        print("❌ Startup aborted due to existing instance")
-        # input("Press Enter to exit...")
+    # � ROBUST INSTANCE CHECK - HTTP + PID based verification
+    print("=" * 60)
+    can_proceed, check_message = check_backend_instance_robust(port=5050)
+    print("=" * 60)
+    
+    if not can_proceed:
+        print(f"❌ Startup aborted: {check_message}")
+        print("💡 Tip: If you believe this is an error, check Task Manager for python.exe processes")
+        # input("\nPress Enter to exit...")
         sys.exit(1)
 
     try:
-        # Initialize streamer instance with instance check
-        print("✅ No conflicting instances found (early check)")
+        # Initialize streamer instance
         print("🔧 Initializing PLCDataStreamer...")
         streamer = PLCDataStreamer()
 
@@ -3946,6 +3967,7 @@ if __name__ == "__main__":
         historical_cache = HistoricalDataCache(backend_logger)
 
         print("✅ Backend initialization complete")
+        print(f"🌐 Starting Flask server on port 5050...")
         main()
 
     except RuntimeError as e:
diff --git a/system_state.json b/system_state.json
index 6793d86..13f99a8 100644
--- a/system_state.json
+++ b/system_state.json
@@ -4,11 +4,11 @@
         "should_stream": false,
         "active_datasets": [
             "DAR",
-            "Fast",
-            "Test"
+            "Test",
+            "Fast"
         ]
     },
     "auto_recovery_enabled": true,
-    "last_update": "2025-08-22T12:14:57.462145",
+    "last_update": "2025-08-22T14:03:25.041057",
     "plotjuggler_path": "C:\\Program Files\\PlotJuggler\\plotjuggler.exe"
 }
\ No newline at end of file
diff --git a/utils/instance_manager.py b/utils/instance_manager.py
new file mode 100644
index 0000000..c9b74a6
--- /dev/null
+++ b/utils/instance_manager.py
@@ -0,0 +1,283 @@
+"""
+🔒 Instance Manager - Robust backend instance control system
+
+This module provides a reliable way to manage backend instances using:
+1. HTTP health check on the backend port
+2. PID-based verification and cleanup
+3. Graceful termination of zombie processes
+
+Key features:
+- Double health check with 5-second intervals for reliability
+- Automatic cleanup of stale lock files
+- Force termination of unresponsive processes
+- Thread-safe operations
+"""
+
+import os
+import sys
+import time
+import json
+import psutil
+import requests
+from typing import Optional, Tuple
+
+
+class InstanceManager:
+    """Manages backend instance lifecycle and prevents duplicate executions"""
+    
+    def __init__(self, 
+                 port: int = 5050, 
+                 lock_file: str = "plc_streamer.lock",
+                 health_endpoint: str = "/api/health",
+                 check_timeout: float = 3.0,
+                 check_interval: float = 5.0):
+        """
+        Initialize the instance manager
+        
+        Args:
+            port: Backend server port to check
+            lock_file: Path to the PID lock file
+            health_endpoint: HTTP endpoint for health checks
+            check_timeout: Timeout for each HTTP request (seconds)
+            check_interval: Time between double-checks (seconds)
+        """
+        self.port = port
+        self.lock_file = lock_file
+        self.health_endpoint = health_endpoint
+        self.check_timeout = check_timeout
+        self.check_interval = check_interval
+        self.base_url = f"http://localhost:{port}"
+        
+    def is_backend_alive_http(self) -> bool:
+        """
+        Check if backend is alive via HTTP health check
+        
+        Returns:
+            True if backend responds to health check, False otherwise
+        """
+        try:
+            response = requests.get(
+                f"{self.base_url}{self.health_endpoint}",
+                timeout=self.check_timeout
+            )
+            # Accept any successful HTTP response (200-299)
+            return 200 <= response.status_code < 300
+            
+        except (requests.RequestException, requests.ConnectionError, 
+                requests.Timeout, requests.ConnectTimeout):
+            return False
+        except Exception as e:
+            print(f"⚠️ Unexpected error during health check: {e}")
+            return False
+    
+    def get_lock_file_pid(self) -> Optional[int]:
+        """
+        Read PID from lock file
+        
+        Returns:
+            PID if lock file exists and is valid, None otherwise
+        """
+        if not os.path.exists(self.lock_file):
+            return None
+            
+        try:
+            with open(self.lock_file, "r") as f:
+                content = f.read().strip()
+                return int(content) if content else None
+        except (ValueError, FileNotFoundError, IOError):
+            return None
+    
+    def is_process_our_backend(self, pid: int) -> bool:
+        """
+        Verify if the process with given PID is our backend application
+        
+        Args:
+            pid: Process ID to check
+            
+        Returns:
+            True if it's our backend process, False otherwise
+        """
+        try:
+            if not psutil.pid_exists(pid):
+                return False
+                
+            proc = psutil.Process(pid)
+            cmdline = " ".join(proc.cmdline()).lower()
+            
+            # Check for our application signatures
+            backend_signatures = [
+                "main.py",
+                "s7_snap7_streamer_n_log",
+                "plc_streamer",
+                "plcdatastreamer"
+            ]
+            
+            return any(sig in cmdline for sig in backend_signatures)
+            
+        except (psutil.NoSuchProcess, psutil.AccessDenied, psutil.ZombieProcess):
+            return False
+        except Exception as e:
+            print(f"⚠️ Error checking process {pid}: {e}")
+            return False
+    
+    def terminate_process_safely(self, pid: int) -> bool:
+        """
+        Safely terminate a process
+        
+        Args:
+            pid: Process ID to terminate
+            
+        Returns:
+            True if process was terminated successfully, False otherwise
+        """
+        try:
+            if not psutil.pid_exists(pid):
+                return True  # Already gone
+                
+            proc = psutil.Process(pid)
+            print(f"🛑 Attempting to terminate process {pid} ({proc.name()})...")
+            
+            # Try graceful termination first
+            proc.terminate()
+            
+            # Wait up to 10 seconds for graceful shutdown
+            try:
+                proc.wait(timeout=10)
+                print(f"✅ Process {pid} terminated gracefully")
+                return True
+            except psutil.TimeoutExpired:
+                # Force kill if graceful didn't work
+                print(f"⚡ Force killing process {pid}...")
+                proc.kill()
+                proc.wait(timeout=5)
+                print(f"💥 Process {pid} force killed")
+                return True
+                
+        except (psutil.NoSuchProcess, psutil.AccessDenied):
+            return True  # Process already gone or no permission
+        except Exception as e:
+            print(f"❌ Error terminating process {pid}: {e}")
+            return False
+    
+    def cleanup_lock_file(self) -> bool:
+        """
+        Remove the lock file
+        
+        Returns:
+            True if lock file was removed or didn't exist, False on error
+        """
+        try:
+            if os.path.exists(self.lock_file):
+                os.remove(self.lock_file)
+                print(f"🧹 Removed lock file: {self.lock_file}")
+            return True
+        except Exception as e:
+            print(f"❌ Error removing lock file: {e}")
+            return False
+    
+    def create_lock_file(self) -> bool:
+        """
+        Create lock file with current process PID
+        
+        Returns:
+            True if lock file was created successfully, False otherwise
+        """
+        try:
+            with open(self.lock_file, "w") as f:
+                f.write(str(os.getpid()))
+            print(f"🔒 Created lock file: {self.lock_file} (PID: {os.getpid()})")
+            return True
+        except Exception as e:
+            print(f"❌ Error creating lock file: {e}")
+            return False
+    
+    def check_and_handle_existing_instance(self) -> Tuple[bool, str]:
+        """
+        Main method: Check for existing instances and handle them
+        
+        Returns:
+            Tuple of (can_proceed, message)
+            - can_proceed: True if this instance can start, False if should exit
+            - message: Description of what happened
+        """
+        print("🔍 Checking for existing backend instances...")
+        
+        # Step 1: First HTTP health check
+        print("📡 Performing first health check...")
+        if self.is_backend_alive_http():
+            return False, f"❌ Another backend is already running on port {self.port}"
+        
+        print(f"⏳ Waiting {self.check_interval} seconds for double-check...")
+        time.sleep(self.check_interval)
+        
+        # Step 2: Second HTTP health check (double verification)
+        print("📡 Performing second health check...")
+        if self.is_backend_alive_http():
+            return False, f"❌ Another backend is confirmed running on port {self.port}"
+        
+        print("✅ No active backend detected via HTTP")
+        
+        # Step 3: Check lock file and handle zombie processes
+        lock_pid = self.get_lock_file_pid()
+        if lock_pid is None:
+            print("📝 No lock file found")
+            return True, "✅ No existing instances detected"
+        
+        print(f"📋 Found lock file with PID: {lock_pid}")
+        
+        # Step 4: Verify if the process is actually our backend
+        if not self.is_process_our_backend(lock_pid):
+            print(f"🧹 PID {lock_pid} is not our backend process")
+            self.cleanup_lock_file()
+            return True, "✅ Cleaned up stale lock file"
+        
+        # Step 5: We have a zombie backend process - terminate it
+        print(f"🧟 Found zombie backend process (PID: {lock_pid})")
+        if self.terminate_process_safely(lock_pid):
+            self.cleanup_lock_file()
+            print("🎯 Successfully cleaned up zombie backend")
+            return True, "✅ Cleaned up zombie backend process"
+        else:
+            return False, f"❌ Failed to cleanup zombie process (PID: {lock_pid})"
+    
+    def initialize_instance(self) -> bool:
+        """
+        Initialize this instance (create lock file)
+        
+        Returns:
+            True if initialization successful, False otherwise
+        """
+        return self.create_lock_file()
+    
+    def cleanup_instance(self) -> bool:
+        """
+        Cleanup this instance (remove lock file)
+        
+        Returns:
+            True if cleanup successful, False otherwise
+        """
+        return self.cleanup_lock_file()
+
+
+def check_backend_instance(port: int = 5050, 
+                          lock_file: str = "plc_streamer.lock") -> Tuple[bool, str]:
+    """
+    Convenience function to check and handle backend instances
+    
+    Args:
+        port: Backend server port
+        lock_file: Lock file path
+        
+    Returns:
+        Tuple of (can_proceed, message)
+    """
+    manager = InstanceManager(port=port, lock_file=lock_file)
+    return manager.check_and_handle_existing_instance()
+
+
+if __name__ == "__main__":
+    # Test the instance manager
+    manager = InstanceManager()
+    can_proceed, message = manager.check_and_handle_existing_instance()
+    print(f"\nResult: {message}")
+    print(f"Can proceed: {can_proceed}")