fix(music): add wav chunk diagnostics and larger chunks

Increase live WAV chunk size to one second and log chunk acceptance, queue depth, and retry state on stations so the HQ speaker path can be diagnosed from runtime logs.

CloudServer/server.js

@@ -324,7 +324,7 @@ async function sendLiveWavChunksToStation(stationName, fallbackWs, task) {
     const sampleRate = 48000;
     const channels = 1;
     const bitsPerSample = 16;
-    const chunkDurationSec = 0.25;
+    const chunkDurationSec = 1.0;
     const chunkBytes = Math.max(4096, Math.floor(sampleRate * channels * (bitsPerSample / 8) * chunkDurationSec));
 
     targetWs.send(JSON.stringify({
@@ -344,7 +344,7 @@ async function sendLiveWavChunksToStation(stationName, fallbackWs, task) {
     const ffmpegArgs = ['-hide_banner', '-loglevel', 'error'];
     if (loop) ffmpegArgs.push('-stream_loop', '-1');
     ffmpegArgs.push('-re', '-i', sourcePath, '-f', 's16le', '-acodec', 'pcm_s16le', '-ac', String(channels), '-ar', String(sampleRate), 'pipe:1');
-    log('INFO', `Live WAV chunk stream start for ${stationName}: ${path.basename(sourcePath)}${loop ? ' (loop)' : ''}`);
+    log('INFO', `Live WAV chunk stream start for ${stationName}: ${path.basename(sourcePath)}${loop ? ' (loop)' : ''} chunk=${chunkDurationSec}s`);
 
     return await new Promise((resolve, reject) => {
         let stderr = '';

station_broadcast.lua

@@ -799,15 +799,29 @@ end
 local function pushWavChunkToSpeakers(payload, playSeq)
     local controller = Peripherals.speakers and Peripherals.speakers[1] or nil
     if controller and type(controller.speakWavAll) == "function" then
+        local retryCount = 0
         while true do
             if shouldStop(playSeq) then return false end
             local ok = false
+            local queueSize = -1
+            local isPlaying = false
             pcall(function()
                 ok = controller.speakWavAll(payload, CONFIG.AUDIO_VOLUME)
+                if type(controller.speakQueueSize) == "function" then
+                    queueSize = tonumber(controller.speakQueueSize()) or -1
+                end
+                if type(controller.speakIsPlaying) == "function" then
+                    isPlaying = controller.speakIsPlaying() and true or false
+                end
             end)
             if ok then
+                Utils.log("INFO", string.format("WAV chunk accepted: bytes=%d queue=%d playing=%s", #payload, queueSize, tostring(isPlaying)))
                 return true
             end
+            retryCount = retryCount + 1
+            if retryCount == 1 or retryCount % 20 == 0 then
+                Utils.log("WARN", string.format("WAV chunk waiting: bytes=%d queue=%d playing=%s retries=%d", #payload, queueSize, tostring(isPlaying), retryCount))
+            end
             if not waitForInterruptibleDelay(playSeq, 0.05) then
                 return false
             end
@@ -820,6 +834,7 @@ local function pushWavChunkToSpeakers(payload, playSeq)
         if name then pending[name] = sp end
     end
 
+    local retryCount = 0
     while next(pending) do
         if shouldStop(playSeq) then return false end
         for name, sp in pairs(pending) do
@@ -831,6 +846,18 @@ local function pushWavChunkToSpeakers(payload, playSeq)
             end)
             if ok then pending[name] = nil end
         end
+        if next(pending) then
+            retryCount = retryCount + 1
+            if retryCount == 1 or retryCount % 20 == 0 then
+                local pendingCount = 0
+                for _ in pairs(pending) do
+                    pendingCount = pendingCount + 1
+                end
+                Utils.log("WARN", string.format("WAV chunk waiting on %d speakers: bytes=%d retries=%d", pendingCount, #payload, retryCount))
+            end
+        else
+            Utils.log("INFO", string.format("WAV chunk accepted by fallback speakers: bytes=%d", #payload))
+        end
         if next(pending) and not waitForInterruptibleDelay(playSeq, 0.05) then
             return false
         end