fix(crash-reporting): stop showing "Orca closed unexpectedly" after the speech engine crashes (#39430)

* fix(crash-reporting): don't report a speech process exit as an Orca crash

* fix(crash-reporting): keep every speech process exit out of crash reports, including OOM

src/main/crash-reporting/process-gone-classification.ts

@@ -1,3 +1,5 @@
+import { STT_UTILITY_PROCESS_NAME } from '../speech/stt-worker-process'
+
 export type ProcessGoneSource = 'renderer' | 'child'
 export type ExpectedTeardownScope = 'none' | 'renderer-reload' | 'app-shutdown'
 
@@ -11,9 +13,22 @@ const RECOVERABLE_UTILITY_SERVICE_NAMES = new Set([
   // Screen-capture service exits are recoverable Chromium churn.
   'video_capture.mojom.VideoCaptureService'
 ])
+// Orca's own utility processes whose exits the app already handles and reports in place.
+const RECOVERABLE_ORCA_UTILITY_NAMES = new Set([STT_UTILITY_PROCESS_NAME])
 const RECOVERABLE_CHILD_PROCESS_REASONS = new Set(['abnormal-exit', 'crashed', 'killed'])
 const NON_RECOVERABLE_RENDERER_REASONS = new Set(['integrity-failure'])
 
+/** Electron's child-process-gone names: a utility's mojo service, and its fork serviceName. */
+export function childProcessNames(details: Record<string, unknown>): {
+  serviceName?: string
+  name?: string
+} {
+  return {
+    serviceName: typeof details.serviceName === 'string' ? details.serviceName : undefined,
+    name: typeof details.name === 'string' ? details.name : undefined
+  }
+}
+
 function isWindowsControlTerminationExitCode(exitCode: number | null): boolean {
   if (exitCode === null) {
     return false
@@ -21,24 +36,34 @@ function isWindowsControlTerminationExitCode(exitCode: number | null): boolean {
   return WINDOWS_CONTROL_TERMINATION_EXIT_CODES.has(exitCode >>> 0)
 }
 
-function isRecoverableChromiumChildProcess({
+function isRecoverableChildProcess({
   source,
   processType,
   serviceName,
+  name,
   reason
 }: {
   source: ProcessGoneSource
   processType?: string
   serviceName?: string
+  name?: string
   reason: string
 }): boolean {
   if (source !== 'child') {
     return false
   }
+  const normalizedProcessType = processType?.toLowerCase()
+  // Orca handles every exit of its own utilities, including OOM and failed launches.
+  if (
+    normalizedProcessType === 'utility' &&
+    name !== undefined &&
+    RECOVERABLE_ORCA_UTILITY_NAMES.has(name)
+  ) {
+    return true
+  }
   if (!RECOVERABLE_CHILD_PROCESS_REASONS.has(reason)) {
     return false
   }
-  const normalizedProcessType = processType?.toLowerCase()
   if (normalizedProcessType && RECOVERABLE_CHILD_PROCESS_TYPES.has(normalizedProcessType)) {
     return true
   }
@@ -54,6 +79,7 @@ export function shouldRecordProcessGoneCrash({
   source,
   processType,
   serviceName,
+  name,
   reason,
   exitCode,
   expectedTeardown
@@ -62,11 +88,12 @@ export function shouldRecordProcessGoneCrash({
   source: ProcessGoneSource
   processType?: string
   serviceName?: string
+  name?: string
   reason: string
   exitCode: number | null
   expectedTeardown: ExpectedTeardownScope
 }): boolean {
-  if (isRecoverableChromiumChildProcess({ source, processType, serviceName, reason })) {
+  if (isRecoverableChildProcess({ source, processType, serviceName, name, reason })) {
     return false
   }
   // Intentional teardown uses killed; explicit crash and OOM reasons remain reportable.

src/main/crash-reporting/process-gone-recorder.test.ts

@@ -64,6 +64,40 @@ afterEach(() => {
 })
 
 describe('recordProcessGoneCrash', () => {
+  it('reports no crash when the speech process dies, since dictation already shows the error', async () => {
+    const record = vi.fn().mockResolvedValue({ id: 'report-1' })
+    const utility = (name: string, reason: string, exitCode: number) =>
+      event({
+        source: 'child',
+        processType: 'Utility',
+        reason,
+        exitCode,
+        details: { name, serviceName: 'node.mojom.NodeService', type: 'Utility' }
+      })
+
+    for (const [reason, exitCode] of [
+      ['killed', 9],
+      ['crashed', 11],
+      ['oom', 1]
+    ] as const) {
+      recordProcessGoneCrash(
+        { record, attachDetails } as never,
+        utility('Orca Speech', reason, exitCode),
+        new ProcessGoneDedupe(),
+        noMinidump
+      )
+    }
+    recordProcessGoneCrash(
+      { record, attachDetails } as never,
+      utility('Some Other Service', 'crashed', 11),
+      new ProcessGoneDedupe(),
+      noMinidump
+    )
+
+    await vi.waitFor(() => expect(record).toHaveBeenCalledOnce())
+    expect(record.mock.calls[0][0].details).toMatchObject({ name: 'Some Other Service' })
+  })
+
   it('still persists the report when the forced trace flush fails', async () => {
     const record = vi.fn().mockResolvedValue({ id: 'report-1' })
     sink.flushMock.mockImplementation(() => {

src/main/crash-reporting/process-gone-recorder.ts

@@ -19,6 +19,7 @@ import {
   trackRendererSiblingAttribution
 } from './process-gone-sibling-attribution'
 import {
+  childProcessNames,
   shouldRecordProcessGoneCrash,
   type ExpectedTeardownScope,
   type ProcessGoneSource
@@ -163,13 +164,12 @@ export function recordProcessGoneCrash(
     return
   }
   const goneAt = Date.now()
-  const serviceName =
-    typeof event.details.serviceName === 'string' ? event.details.serviceName : undefined
+  const names = childProcessNames(event.details)
   if (event.source === 'child') {
     correlateChildProcessDeath({
       at: goneAt,
       processType: event.processType,
-      ...(serviceName ? { serviceName } : {}),
+      ...(names.serviceName ? { serviceName: names.serviceName } : {}),
       reason: event.reason,
       exitCode: event.exitCode
     })
@@ -181,7 +181,7 @@ export function recordProcessGoneCrash(
       platform: process.platform,
       source: event.source,
       processType: event.processType,
-      serviceName,
+      ...names,
       reason: event.reason,
       exitCode: event.exitCode,
       expectedTeardown: event.expectedTeardown

src/main/speech/stt-worker-process.ts

@@ -3,6 +3,9 @@ import type { MessagePortMain } from 'electron'
 import type { WorkerRequestTransport } from '../worker-threads/worker-thread-transport'
 import type { RecognizerConfigInput } from './stt-worker-model-config'
 
+/** Electron reports it as the utility process's name when it exits. */
+export const STT_UTILITY_PROCESS_NAME = 'Orca Speech'
+
 export const STT_WORKER_EXITED_ERROR = 'The speech engine stopped unexpectedly. Try again.'
 export const STT_WORKER_HUNG_ERROR = 'The speech engine stopped responding. Try again.'
 

src/main/speech/stt-worker-utility-process.ts

@@ -2,6 +2,7 @@ import { utilityProcess } from 'electron'
 import { getSttWorkerPath } from './stt-worker-paths'
 import {
   logSttWorkerStderr,
+  STT_UTILITY_PROCESS_NAME,
   SttWorkerChildProcess,
   type SttWorkerProcess
 } from './stt-worker-process'
@@ -9,7 +10,7 @@ import {
 /** A native crash or hang in the recognizer stays out of the app's main process. */
 export function spawnSttUtilityProcess(): SttWorkerProcess {
   const child = utilityProcess.fork(getSttWorkerPath(), [], {
-    serviceName: 'Orca Speech',
+    serviceName: STT_UTILITY_PROCESS_NAME,
     stdio: ['ignore', 'ignore', 'pipe']
   })
   const worker = new SttWorkerChildProcess({