Fix parallel session crash: coalesce state notifications + dispose Process handles

PolyPilot.Tests/StateChangeCoalescerTests.cs

@@ -0,0 +1,94 @@
+using Microsoft.Extensions.DependencyInjection;
+using PolyPilot.Services;
+
+namespace PolyPilot.Tests;
+
+/// <summary>
+/// Tests for NotifyStateChangedCoalesced — verifies that rapid-fire calls
+/// coalesce into fewer OnStateChanged invocations.
+/// </summary>
+public class StateChangeCoalescerTests
+{
+    private readonly StubChatDatabase _chatDb = new();
+    private readonly StubServerManager _serverManager = new();
+    private readonly StubWsBridgeClient _bridgeClient = new();
+    private readonly StubDemoService _demoService = new();
+    private readonly RepoManager _repoManager = new();
+    private readonly IServiceProvider _serviceProvider;
+
+    public StateChangeCoalescerTests()
+    {
+        var services = new ServiceCollection();
+        _serviceProvider = services.BuildServiceProvider();
+    }
+
+    private CopilotService CreateService() =>
+        new CopilotService(_chatDb, _serverManager, _bridgeClient, _repoManager, _serviceProvider, _demoService);
+
+    [Fact]
+    public async Task RapidCalls_CoalesceIntoSingleNotification()
+    {
+        var svc = CreateService();
+        int fireCount = 0;
+        svc.OnStateChanged += () => Interlocked.Increment(ref fireCount);
+
+        // Fire 20 rapid coalesced notifications
+        for (int i = 0; i < 20; i++)
+            svc.NotifyStateChangedCoalesced();
+
+        // Wait for the coalesce timer to fire (150ms + margin)
+        await Task.Delay(300);
+
+        // Should have coalesced into 1 notification (not 20)
+        Assert.InRange(fireCount, 1, 3);
+    }
+
+    [Fact]
+    public async Task SingleCall_FiresExactlyOnce()
+    {
+        var svc = CreateService();
+        int fireCount = 0;
+        svc.OnStateChanged += () => Interlocked.Increment(ref fireCount);
+
+        svc.NotifyStateChangedCoalesced();
+        await Task.Delay(300);
+
+        Assert.Equal(1, fireCount);
+    }
+
+    [Fact]
+    public async Task SeparateBursts_FireSeparately()
+    {
+        var svc = CreateService();
+        int fireCount = 0;
+        svc.OnStateChanged += () => Interlocked.Increment(ref fireCount);
+
+        // First burst
+        for (int i = 0; i < 10; i++)
+            svc.NotifyStateChangedCoalesced();
+        await Task.Delay(300);
+
+        // Second burst after timer has fired
+        for (int i = 0; i < 10; i++)
+            svc.NotifyStateChangedCoalesced();
+        await Task.Delay(300);
+
+        // Each burst should produce ~1 notification
+        Assert.InRange(fireCount, 2, 4);
+    }
+
+    [Fact]
+    public void ImmediateNotify_StillWorks()
+    {
+        var svc = CreateService();
+        int fireCount = 0;
+        svc.OnStateChanged += () => Interlocked.Increment(ref fireCount);
+
+        // Direct OnStateChanged (not coalesced) should fire immediately
+        svc.NotifyStateChanged();
+        Assert.Equal(1, fireCount);
+
+        svc.NotifyStateChanged();
+        Assert.Equal(2, fireCount);
+    }
+}

PolyPilot/Services/CopilotService.Bridge.cs

@@ -49,7 +49,7 @@ private async Task InitializeRemoteAsync(ConnectionSettings settings, Cancellati
         _bridgeClient.OnStateChanged += () =>
         {
             SyncRemoteSessions();
-            InvokeOnUI(() => OnStateChanged?.Invoke());
+            NotifyStateChangedCoalesced();
         };
         _bridgeClient.OnReposListReceived += payload =>
         {

PolyPilot/Services/CopilotService.Events.cs

@@ -308,7 +308,7 @@ void Invoke(Action action)
                 if (state.Info.ProcessingPhase < 3)
                 {
                     state.Info.ProcessingPhase = 3; // Working
-                    Invoke(() => OnStateChanged?.Invoke());
+                    NotifyStateChangedCoalesced();
                 }
                 var startToolName = toolStart.Data.ToolName ?? "unknown";
                 var startCallId = toolStart.Data.ToolCallId ?? "";
@@ -419,7 +419,7 @@ void Invoke(Action action)
                 Invoke(() =>
                 {
                     if (isPermissionDenial)
-                        OnStateChanged?.Invoke();
+                        NotifyStateChangedCoalesced();
                     OnToolCompleted?.Invoke(sessionName, completeCallId, resultStr, !hasError);
                     OnActivity?.Invoke(sessionName, hasError ? "❌ Tool failed" : "✅ Tool completed");
                 });
@@ -449,7 +449,7 @@ void Invoke(Action action)
                 {
                     OnTurnStart?.Invoke(sessionName);
                     OnActivity?.Invoke(sessionName, "🤔 Thinking...");
-                    if (phaseAdvancedToThinking) OnStateChanged?.Invoke();
+                    if (phaseAdvancedToThinking) NotifyStateChangedCoalesced();
                 });
                 break;
 

PolyPilot/Services/CopilotService.cs

@@ -202,6 +202,7 @@ internal CopilotService(IChatDatabase chatDb, IServerManager serverManager, IWsB
         _serviceProvider = serviceProvider;
         _demoService = demoService;
         _codespaceService = codespaceService ?? new CodespaceService();
+        _stateChangedCoalesceTimer = new Timer(FireCoalescedStateChanged, null, Timeout.Infinite, Timeout.Infinite);
         try { _usageStats = serviceProvider?.GetService(typeof(UsageStatsService)) as UsageStatsService; } catch { }
     }
 
@@ -328,6 +329,37 @@ internal int RemoveGroupsWhere(Predicate<SessionGroup> match)
 
     public event Action? OnStateChanged;
     public void NotifyStateChanged() => OnStateChanged?.Invoke();
+
+    /// <summary>
+    /// Coalesced state change notification. Batches rapid-fire events (tool starts,
+    /// phase changes, turn starts) into a single OnStateChanged callback within the
+    /// coalesce window. Use this for high-frequency, non-critical state updates.
+    /// Critical events (completion, errors, session switches) should still call
+    /// OnStateChanged?.Invoke() directly for immediate UI response.
+    /// </summary>
+    private Timer? _stateChangedCoalesceTimer;
+    private const int StateChangedCoalesceMs = 150;
+    private int _stateChangedPending; // 0 = idle, 1 = pending
+
+    internal void NotifyStateChangedCoalesced()
+    {
+        // Mark as pending — if already pending, the timer will fire and pick it up
+        if (Interlocked.CompareExchange(ref _stateChangedPending, 1, 0) == 0)
+        {
+            try
+            {
+                _stateChangedCoalesceTimer?.Change(StateChangedCoalesceMs, Timeout.Infinite);
+            }
+            catch (ObjectDisposedException) { }
+        }
+    }
+
+    private void FireCoalescedStateChanged(object? _)
+    {
+        Interlocked.Exchange(ref _stateChangedPending, 0);
+        InvokeOnUI(() => OnStateChanged?.Invoke());
+    }
+
     public event Action<string, string>? OnContentReceived; // sessionName, content
     public event Action<string, string>? OnError; // sessionName, error
     public event Action<string, string>? OnSessionComplete; // sessionName, summary
@@ -3371,7 +3403,10 @@ public async ValueTask DisposeAsync()
         _saveUiStateDebounce?.Dispose();
         _saveUiStateDebounce = null;
         FlushUiState();
-
+
+        _stateChangedCoalesceTimer?.Dispose();
+        _stateChangedCoalesceTimer = null;
+
         foreach (var state in _sessions.Values)
         {
             CancelProcessingWatchdog(state);

PolyPilot/Services/DevTunnelService.cs

@@ -279,8 +279,9 @@ private async Task<bool> TryHostTunnelAsync(ConnectionSettings settings)
         if (_hostProcess != null && !_hostProcess.HasExited)
         {
             try { _hostProcess.Kill(entireProcessTree: true); } catch { }
-            _hostProcess = null;
         }
+        _hostProcess?.Dispose();
+        _hostProcess = null;
 
         var hostArgs = _tunnelId != null
             ? $"host {_tunnelId}"
@@ -458,6 +459,7 @@ public void Stop()
                 _hostProcess.Kill(entireProcessTree: true);
                 Console.WriteLine("[DevTunnel] Host process killed");
             }
+            _hostProcess?.Dispose();
         }
         catch (Exception ex)
         {

PolyPilot/Services/ServerManager.cs

@@ -95,15 +95,13 @@ public async Task<bool> StartServerAsync(int port = 4321)
             SavePidFile(process.Id, port);
             Console.WriteLine($"[ServerManager] Started copilot server PID {process.Id} on port {port}");
 
-            // Detach stdout/stderr readers so they don't hold the process
-            _ = Task.Run(async () =>
-            {
-                try { while (await process.StandardOutput.ReadLineAsync() != null) { } } catch { }
-            });
-            _ = Task.Run(async () =>
-            {
-                try { while (await process.StandardError.ReadLineAsync() != null) { } } catch { }
-            });
+            // Drain stdout/stderr in parallel; dispose process handle when both streams close.
+            // The server process itself keeps running — we only release the OS handle.
+            // Must be parallel: sequential draining deadlocks if stderr fills its pipe buffer
+            // while stdout drain blocks waiting for the process to exit.
+            var t1 = Task.Run(async () => { try { while (await process.StandardOutput.ReadLineAsync() != null) { } } catch { } });
+            var t2 = Task.Run(async () => { try { while (await process.StandardError.ReadLineAsync() != null) { } } catch { } });
+            _ = Task.WhenAll(t1, t2).ContinueWith(_ => process.Dispose());
 
             // Wait for server to become available
             for (int i = 0; i < 15; i++)
@@ -140,6 +138,7 @@ public void StopServer()
             {
                 var process = Process.GetProcessById(pid.Value);
                 process.Kill();
+                process.Dispose();
                 Console.WriteLine($"[ServerManager] Killed server PID {pid}");
             }
             catch (Exception ex)