fix: pipeline_state.json daily reset — timestamp-based staleness (#650)

Pipeline states from previous days are now treated as stale:
- complete/failed from yesterday → not_started (allows re-run)
- running for >6h → not_started (likely crashed)

Changes:
- Added state_is_stale() function checking state date vs today
- Added reset_stale_states() called at start of each scheduler run
- is_pipeline_complete() and is_pipeline_running() check staleness
- --status shows '(stale)' indicator for outdated states
- Running states auto-expire after 6 hours (crash recovery)

cron/pipeline-scheduler.yml

@@ -0,0 +1,9 @@
+- name: Nightly Pipeline Scheduler
+  schedule: '*/30 18-23,0-8 * * *' # Every 30 min, off-peak hours only
+  tasks:
+    - name: Check and start pipelines
+      shell: "bash scripts/nightly-pipeline-scheduler.sh"
+      env:
+        PIPELINE_TOKEN_LIMIT: "500000"
+        PIPELINE_PEAK_START: "9"
+        PIPELINE_PEAK_END: "18"

scripts/nightly-pipeline-scheduler.md

@@ -0,0 +1,50 @@
+# Nightly Pipeline Scheduler
+
+Auto-starts batch pipelines when inference is available.
+
+## What It Does
+
+1. Checks inference provider health (OpenRouter, Ollama, RunPod)
+2. Checks if it's off-peak hours (configurable, default: after 6PM)
+3. Checks interactive session load (don't fight with live users)
+4. Checks daily token budget (configurable limit)
+5. Starts the highest-priority incomplete pipeline
+
+## Pipeline Priority Order
+
+| Priority | Pipeline | Deps | Max Tokens |
+|----------|----------|------|------------|
+| 1 | playground-factory | none | 100,000 |
+| 2 | training-factory | none | 150,000 |
+| 3 | knowledge-mine | training-factory running | 80,000 |
+| 4 | adversary | knowledge-mine running | 50,000 |
+| 5 | codebase-genome | none | 120,000 |
+
+## Usage
+
+```bash
+# Normal run (used by cron)
+./scripts/nightly-pipeline-scheduler.sh
+
+# Dry run (show what would start)
+./scripts/nightly-pipeline-scheduler.sh --dry-run
+
+# Status report
+./scripts/nightly-pipeline-scheduler.sh --status
+
+# Force start during peak hours
+./scripts/nightly-pipeline-scheduler.sh --force
+```
+
+## Configuration
+
+Set via environment variables:
+- `PIPELINE_TOKEN_LIMIT`: Daily token budget (default: 500,000)
+- `PIPELINE_PEAK_START`: Peak hours start (default: 9)
+- `PIPELINE_PEAK_END`: Peak hours end (default: 18)
+- `HERMES_HOME`: Hermes home directory (default: ~/.hermes)
+
+## Cron
+
+Runs every 30 minutes. Off-peak only (unless --force).
+See `cron/pipeline-scheduler.yml`.

scripts/nightly-pipeline-scheduler.sh

@@ -0,0 +1,523 @@
+#!/usr/bin/env bash
+# nightly-pipeline-scheduler.sh — Auto-start batch pipelines when inference is available.
+#
+# Checks provider health, pipeline progress, token budget, and interactive load.
+# Starts the highest-priority incomplete pipeline that can run.
+#
+# FIX #650: Pipeline states are date-aware. A "complete" or "failed" state from
+# a previous day is treated as stale (not_started) so pipelines can re-run daily.
+# Running states older than 6 hours are also treated as stale (likely crashed).
+#
+# Usage:
+#   ./scripts/nightly-pipeline-scheduler.sh          # Normal run
+#   ./scripts/nightly-pipeline-scheduler.sh --dry-run # Show what would start
+#   ./scripts/nightly-pipeline-scheduler.sh --status  # Pipeline status report
+
+set -euo pipefail
+
+# --- Configuration ---
+HERMES_HOME="${HERMES_HOME:-$HOME/.hermes}"
+BUDGET_FILE="${HERMES_HOME}/pipeline_budget.json"
+STATE_FILE="${HERMES_HOME}/pipeline_state.json"
+LOG_FILE="${HERMES_HOME}/logs/pipeline-scheduler.log"
+TOKEN_DAILY_LIMIT="${PIPELINE_TOKEN_LIMIT:-500000}"
+PEAK_HOURS_START="${PIPELINE_PEAK_START:-9}"
+PEAK_HOURS_END="${PIPELINE_PEAK_END:-18}"
+
+# Pipeline definitions (priority order)
+# Each pipeline: name, script, max_tokens, dependencies
+PIPELINES=(
+    "playground-factory|scripts/pipeline_playground_factory.sh|100000|none"
+    "training-factory|scripts/pipeline_training_factory.sh|150000|none"
+    "knowledge-mine|scripts/pipeline_knowledge_mine.sh|80000|training-factory"
+    "adversary|scripts/pipeline_adversary.sh|50000|knowledge-mine"
+    "codebase-genome|scripts/pipeline_codebase_genome.sh|120000|none"
+)
+
+# --- Colors ---
+RED='\033[0;31m'
+GREEN='\033[0;32m'
+YELLOW='\033[0;33m'
+CYAN='\033[0;36m'
+NC='\033[0m'
+
+# --- Helpers ---
+now_hour() { date +%-H; }
+is_peak_hours() {
+    local h=$(now_hour)
+    [[ $h -ge $PEAK_HOURS_START && $h -lt $PEAK_HOURS_END ]]
+}
+
+ensure_dirs() {
+    mkdir -p "$(dirname "$LOG_FILE")" "$(dirname "$BUDGET_FILE")" "$(dirname "$STATE_FILE")"
+}
+
+log() { echo "[$(date '+%Y-%m-%d %H:%M:%S')] $*" | tee -a "$LOG_FILE"; }
+
+# --- FIX #650: Staleness detection ---
+#
+# A pipeline state is "stale" if:
+#   - complete/failed: state was set on a different calendar day
+#   - running: state was set more than 6 hours ago (likely crashed)
+#
+# Stale states are treated as not_started, allowing the pipeline to re-run.
+today_date() { date +%Y-%m-%d; }
+
+state_is_stale() {
+    local pipeline="$1"
+    python3 -c "
+import json, os, sys
+from datetime import datetime, timedelta
+
+path = '$STATE_FILE'
+today = '$(today_date)'
+
+if not os.path.exists(path):
+    sys.exit(0)  # no state file = not stale (not_started)
+
+with open(path) as f:
+    d = json.load(f)
+
+entry = d.get('$pipeline', {})
+state = entry.get('state', 'not_started')
+updated = entry.get('updated', '')
+
+if state == 'not_started':
+    sys.exit(0)  # not stale
+
+if not updated:
+    sys.exit(1)  # no timestamp = treat as stale
+
+try:
+    state_date = updated[:10]  # YYYY-MM-DD from ISO timestamp
+    state_time = datetime.fromisoformat(updated.replace('Z', '+00:00'))
+except (ValueError, IndexError):
+    sys.exit(1)  # unparseable = stale
+
+if state in ('complete', 'failed'):
+    # Stale if not from today
+    if state_date != today:
+        print(f'STALE: {state} from {state_date} (today is {today})', file=sys.stderr)
+        sys.exit(1)
+    sys.exit(0)  # today's state is fresh
+
+if state == 'running':
+    # Stale if older than 6 hours (likely crashed)
+    now = datetime.now(state_time.tzinfo)
+    age_hours = (now - state_time).total_seconds() / 3600
+    if age_hours > 6:
+        print(f'STALE: running for {age_hours:.1f}h (max 6h)', file=sys.stderr)
+        sys.exit(1)
+    sys.exit(0)  # recently started
+
+sys.exit(0)
+" 2>/dev/null
+    return $?
+}
+
+get_budget_used_today() {
+    if [[ -f "$BUDGET_FILE" ]]; then
+        local today=$(date +%Y-%m-%d)
+        python3 -c "
+import json, sys
+with open('$BUDGET_FILE') as f:
+    d = json.load(f)
+print(d.get('daily', {}).get('$today', {}).get('tokens_used', 0))
+" 2>/dev/null || echo 0
+    else
+        echo 0
+    fi
+}
+
+get_budget_remaining() {
+    local used=$(get_budget_used_today)
+    echo $((TOKEN_DAILY_LIMIT - used))
+}
+
+update_budget() {
+    local pipeline="$1"
+    local tokens="$2"
+    local today=$(date +%Y-%m-%d)
+    python3 -c "
+import json, os
+path = '$BUDGET_FILE'
+d = {}
+if os.path.exists(path):
+    with open(path) as f:
+        d = json.load(f)
+daily = d.setdefault('daily', {})
+day = daily.setdefault('$today', {'tokens_used': 0, 'pipelines': {}})
+day['tokens_used'] = day.get('tokens_used', 0) + $tokens
+day['pipelines']['$pipeline'] = day['pipelines'].get('$pipeline', 0) + $tokens
+with open(path, 'w') as f:
+    json.dump(d, f, indent=2)
+"
+}
+
+get_pipeline_state() {
+    if [[ -f "$STATE_FILE" ]]; then
+        cat "$STATE_FILE"
+    else
+        echo "{}"
+    fi
+}
+
+set_pipeline_state() {
+    local pipeline="$1"
+    local state="$2"  # running, complete, failed, skipped
+    python3 -c "
+import json, os
+path = '$STATE_FILE'
+d = {}
+if os.path.exists(path):
+    with open(path) as f:
+        d = json.load(f)
+d['$pipeline'] = {'state': '$state', 'updated': '$(date -Iseconds)'}
+with open(path, 'w') as f:
+    json.dump(d, f, indent=2)
+"
+}
+
+# FIX #650: is_pipeline_complete checks staleness
+is_pipeline_complete() {
+    local pipeline="$1"
+    # If stale, it's not complete
+    if ! state_is_stale "$pipeline" 2>/dev/null; then
+        # Fresh state — check if actually complete
+        python3 -c "
+import json, os
+path = '$STATE_FILE'
+if not os.path.exists(path):
+    print('false')
+else:
+    with open(path) as f:
+        d = json.load(f)
+    state = d.get('$pipeline', {}).get('state', 'not_started')
+    print('true' if state == 'complete' else 'false')
+" 2>/dev/null || echo false
+    else
+        echo false  # Stale = not complete
+    fi
+}
+
+# FIX #650: is_pipeline_running checks staleness
+is_pipeline_running() {
+    local pipeline="$1"
+    if ! state_is_stale "$pipeline" 2>/dev/null; then
+        python3 -c "
+import json, os
+path = '$STATE_FILE'
+if not os.path.exists(path):
+    print('false')
+else:
+    with open(path) as f:
+        d = json.load(f)
+    state = d.get('$pipeline', {}).get('state', 'not_started')
+    print('true' if state == 'running' else 'false')
+" 2>/dev/null || echo false
+    else
+        echo false  # Stale = not running
+    fi
+}
+
+check_dependency() {
+    local dep="$1"
+    if [[ "$dep" == "none" ]]; then
+        return 0
+    fi
+    # For knowledge-mine: training-factory must be running or complete
+    if [[ "$dep" == "training-factory" ]]; then
+        local state=$(python3 -c "
+import json, os
+path = '$STATE_FILE'
+if not os.path.exists(path):
+    print('not_started')
+else:
+    with open(path) as f:
+        d = json.load(f)
+    print(d.get('training-factory', {}).get('state', 'not_started'))
+" 2>/dev/null || echo "not_started")
+        [[ "$state" == "running" || "$state" == "complete" ]]
+        return $?
+    fi
+    # For adversary: knowledge-mine must be at least 50% done
+    # Simplified: check if it's running (we'd need progress tracking for 50%)
+    if [[ "$dep" == "knowledge-mine" ]]; then
+        local state=$(python3 -c "
+import json, os
+path = '$STATE_FILE'
+if not os.path.exists(path):
+    print('not_started')
+else:
+    with open(path) as f:
+        d = json.load(f)
+    print(d.get('knowledge-mine', {}).get('state', 'not_started'))
+" 2>/dev/null || echo "not_started")
+        [[ "$state" == "running" || "$state" == "complete" ]]
+        return $?
+    fi
+    return 0
+}
+
+check_inference_available() {
+    # Check if any inference provider is responding
+    # 1. Check OpenRouter
+    local or_ok=$(curl -s -o /dev/null -w "%{http_code}" \
+        --connect-timeout 5 "https://openrouter.ai/api/v1/models" 2>/dev/null || echo "000")
+
+    # 2. Check local Ollama
+    local ollama_ok=$(curl -s -o /dev/null -w "%{http_code}" \
+        --connect-timeout 5 "http://localhost:11434/api/tags" 2>/dev/null || echo "000")
+
+    # 3. Check RunPod (if configured)
+    local runpod_ok="000"
+    if [[ -n "${RUNPOD_ENDPOINT:-}" ]]; then
+        runpod_ok=$(curl -s -o /dev/null -w "%{http_code}" \
+            --connect-timeout 5 "$RUNPOD_ENDPOINT/health" 2>/dev/null || echo "000")
+    fi
+
+    if [[ "$or_ok" == "200" || "$ollama_ok" == "200" || "$runpod_ok" == "200" ]]; then
+        return 0
+    fi
+    return 1
+}
+
+check_interactive_load() {
+    # Check if there are active interactive sessions (don't fight with live users)
+    # Look for tmux panes with active hermes sessions
+    local active=$(tmux list-panes -a -F '#{pane_pid} #{pane_current_command}' 2>/dev/null \
+        | grep -c "hermes\|python3" || echo 0)
+
+    # If more than 3 interactive sessions, skip pipeline start
+    if [[ $active -gt 3 ]]; then
+        return 1
+    fi
+    return 0
+}
+
+start_pipeline() {
+    local name="$1"
+    local script="$2"
+    local max_tokens="$3"
+    local budget_remaining="$4"
+    local mode="${5:-run}"
+
+    if [[ "$budget_remaining" -lt "$max_tokens" ]]; then
+        log "SKIP $name: insufficient budget ($budget_remaining < $max_tokens tokens)"
+        return 1
+    fi
+
+    if [[ ! -f "$script" ]]; then
+        log "SKIP $name: script not found ($script)"
+        return 1
+    fi
+
+    if [[ "$mode" == "dry-run" ]]; then
+        log "DRY-RUN: Would start $name (budget: $budget_remaining, needs: $max_tokens)"
+        return 0
+    fi
+
+    log "START $name (budget: $budget_remaining, max_tokens: $max_tokens)"
+    set_pipeline_state "$name" "running"
+
+    # Run in background, capture output
+    local log_path="${HERMES_HOME}/logs/pipeline-${name}.log"
+    bash "$script" --max-tokens "$max_tokens" >> "$log_path" 2>&1 &
+    local pid=$!
+
+    # Wait a moment to check if it started OK
+    sleep 2
+    if kill -0 $pid 2>/dev/null; then
+        log "RUNNING $name (PID: $pid, log: $log_path)"
+        # Record the PID
+        python3 -c "
+import json, os
+path = '$STATE_FILE'
+d = {}
+if os.path.exists(path):
+    with open(path) as f:
+        d = json.load(f)
+d['$name']['pid'] = $pid
+with open(path, 'w') as f:
+    json.dump(d, f, indent=2)
+"
+        return 0
+    else
+        log "FAIL $name: script exited immediately"
+        set_pipeline_state "$name" "failed"
+        return 1
+    fi
+}
+
+# FIX #650: Daily reset — purge stale states at the start of each run
+reset_stale_states() {
+    if [[ ! -f "$STATE_FILE" ]]; then
+        return
+    fi
+    python3 -c "
+import json, os, sys
+from datetime import datetime
+
+path = '$STATE_FILE'
+today = '$(today_date)'
+
+with open(path) as f:
+    d = json.load(f)
+
+changed = False
+cleaned = []
+for name, entry in list(d.items()):
+    state = entry.get('state', '')
+    updated = entry.get('updated', '')
+
+    if state in ('complete', 'failed') and updated:
+        state_date = updated[:10]
+        if state_date != today:
+            del d[name]
+            changed = True
+            cleaned.append(name)
+
+    elif state == 'running' and updated:
+        try:
+            state_time = datetime.fromisoformat(updated.replace('Z', '+00:00'))
+            now = datetime.now(state_time.tzinfo)
+            age_hours = (now - state_time).total_seconds() / 3600
+            if age_hours > 6:
+                del d[name]
+                changed = True
+                cleaned.append(f'{name}(stale-running)')
+        except (ValueError, IndexError):
+            del d[name]
+            changed = True
+            cleaned.append(f'{name}(bad-timestamp)')
+
+if changed:
+    with open(path, 'w') as f:
+        json.dump(d, f, indent=2)
+    print(f'Reset {len(cleaned)} stale pipelines: {', '.join(cleaned)}')
+else:
+    print('No stale pipeline states')
+" 2>>"$LOG_FILE"
+}
+
+# --- Main ---
+main() {
+    local mode="${1:-run}"
+    ensure_dirs
+
+    log "=== Pipeline Scheduler ($mode) ==="
+
+    # FIX #650: Reset stale states first
+    reset_stale_states
+
+    # Check 1: Is inference available?
+    if ! check_inference_available; then
+        log "No inference provider available. Skipping all pipelines."
+        exit 0
+    fi
+    log "Inference: AVAILABLE"
+
+    # Check 2: Is it peak hours?
+    if is_peak_hours && [[ "$mode" != "--force" ]]; then
+        local h=$(now_hour)
+        log "Peak hours ($h:00). Skipping pipeline start. Use --force to override."
+        exit 0
+    fi
+    log "Off-peak: OK"
+
+    # Check 3: Interactive load
+    if ! check_interactive_load && [[ "$mode" != "--force" ]]; then
+        log "High interactive load. Skipping pipeline start."
+        exit 0
+    fi
+    log "Interactive load: OK"
+
+    # Check 4: Token budget
+    local budget=$(get_budget_remaining)
+    log "Token budget remaining: $budget / $TOKEN_DAILY_LIMIT"
+
+    if [[ $budget -le 0 ]]; then
+        log "Daily token budget exhausted. Stopping."
+        exit 0
+    fi
+
+    # Check 5: Pipeline status
+    if [[ "$mode" == "--status" ]]; then
+        echo -e "${CYAN}Pipeline Status:${NC}"
+        echo "────────────────────────────────────────────────────"
+        for entry in "${PIPELINES[@]}"; do
+            IFS='|' read -r name script max_tokens dep <<< "$entry"
+            local state=$(python3 -c "
+import json, os
+path = '$STATE_FILE'
+if not os.path.exists(path):
+    print('not_started')
+else:
+    with open(path) as f:
+        d = json.load(f)
+    print(d.get('$name', {}).get('state', 'not_started'))
+" 2>/dev/null || echo "not_started")
+
+            # Check staleness for display
+            if [[ "$state" == "complete" || "$state" == "failed" || "$state" == "running" ]]; then
+                if ! state_is_stale "$name" 2>/dev/null; then
+                    : # fresh
+                else
+                    state="${state} (stale)"
+                fi
+            fi
+
+            local color=$NC
+            case "$state" in
+                running*)  color=$YELLOW ;;
+                complete*) color=$GREEN ;;
+                failed*)   color=$RED ;;
+            esac
+            printf "  %-25s %b%s%b (max: %s tokens, dep: %s)\n" "$name" "$color" "$state" "$NC" "$max_tokens" "$dep"
+        done
+        echo "────────────────────────────────────────────────────"
+        echo "  Budget: $budget / $TOKEN_DAILY_LIMIT tokens remaining"
+        echo "  Peak hours: $PEAK_HOURS_START:00 - $PEAK_HOURS_END:00"
+        exit 0
+    fi
+
+    # Find and start the highest-priority incomplete pipeline
+    local started=0
+    for entry in "${PIPELINES[@]}"; do
+        IFS='|' read -r name script max_tokens dep <<< "$entry"
+
+        # Skip if already running or complete (staleness already handled above)
+        if [[ "$(is_pipeline_running $name)" == "true" ]]; then
+            log "SKIP $name: already running"
+            continue
+        fi
+        if [[ "$(is_pipeline_complete $name)" == "true" ]]; then
+            log "SKIP $name: already complete"
+            continue
+        fi
+
+        # Check dependency
+        if ! check_dependency "$dep"; then
+            log "SKIP $name: dependency $dep not met"
+            continue
+        fi
+
+        # Try to start
+        if start_pipeline "$name" "$script" "$max_tokens" "$budget" "$mode"; then
+            started=1
+            # Only start one pipeline per run (let it claim tokens before next check)
+            # Exception: playground-factory and training-factory can run in parallel
+            if [[ "$name" != "playground-factory" && "$name" != "training-factory" ]]; then
+                break
+            fi
+        fi
+    done
+
+    if [[ $started -eq 0 ]]; then
+        log "No pipelines to start (all complete, running, or blocked)."
+    fi
+
+    log "=== Pipeline Scheduler done ==="
+}
+
+main "$@"