fix: auto-repair missing plugins on startup (#293)

* fix: auto-repair missing plugins and graceful config fallback

Plugins whose directories are missing (failed update, migration, etc.)
now get automatically reinstalled from the store on startup. The config
endpoint no longer returns a hard 500 when a schema is unavailable —
it falls back to conservative key-name-based masking so the settings
page stays functional.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

* fix: handle ledmatrix- prefix in plugin updates and reconciliation

The store registry uses unprefixed IDs (e.g., 'weather') while older
installs used prefixed config keys (e.g., 'ledmatrix-weather'). Both
update_plugin() and auto-repair now try the unprefixed ID as a fallback
when the prefixed one isn't found in the registry.

Also filters system config keys (schedule, display, etc.) from
reconciliation to avoid false positives.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

* fix: address code review findings for plugin auto-repair

- Move backup-folder filter from _get_config_state to _get_disk_state
  where the artifact actually lives
- Run startup reconciliation in a background thread so requests aren't
  blocked by plugin reinstallation
- Set _reconciliation_done only after success so failures allow retries
- Replace print() with proper logger in reconciliation
- Wrap load_schema in try/except so exceptions fall through to
  conservative masking instead of 500
- Handle list values in _conservative_mask_config for nested secrets
- Remove duplicate import re

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

* fix: add thread-safe locking to PluginManager and fix reconciliation retry

PluginManager thread safety:
- Add RLock protecting plugin_manifests and plugin_directories
- Build scan results locally in _scan_directory_for_plugins, then update
  shared state under lock
- Protect reads in get_plugin_info, get_all_plugin_info,
  get_plugin_directory, get_plugin_display_modes, find_plugin_for_mode
- Protect manifest mutation in reload_plugin
- Prevents races between background reconciliation thread and request
  handlers reading plugin state

Reconciliation retry:
- Clear _reconciliation_started on exception so next request retries
- Check result.reconciliation_successful before marking done
- Reset _reconciliation_started on non-success results to allow retry

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

---------

Co-authored-by: Claude Opus 4.6 <noreply@anthropic.com>

src/plugin_system/plugin_manager.py

@@ -14,6 +14,7 @@ import importlib.util
 import sys
 import subprocess
 import time
+import threading
 from pathlib import Path
 from typing import Dict, List, Optional, Any
 import logging
@@ -74,6 +75,10 @@ class PluginManager:
         self.state_manager = PluginStateManager(logger=self.logger)
         self.schema_manager = SchemaManager(plugins_dir=self.plugins_dir, logger=self.logger)
         
+        # Lock protecting plugin_manifests and plugin_directories from
+        # concurrent mutation (background reconciliation) and reads (requests).
+        self._discovery_lock = threading.RLock()
+
         # Active plugins
         self.plugins: Dict[str, Any] = {}
         self.plugin_manifests: Dict[str, Dict[str, Any]] = {}
@@ -94,23 +99,27 @@ class PluginManager:
     def _scan_directory_for_plugins(self, directory: Path) -> List[str]:
         """
         Scan a directory for plugins.
-        
+
         Args:
             directory: Directory to scan
-            
+
         Returns:
             List of plugin IDs found
         """
         plugin_ids = []
-        
+
         if not directory.exists():
             return plugin_ids
-        
+
+        # Build new state locally before acquiring lock
+        new_manifests: Dict[str, Dict[str, Any]] = {}
+        new_directories: Dict[str, Path] = {}
+
         try:
             for item in directory.iterdir():
                 if not item.is_dir():
                     continue
-                
+
                 manifest_path = item / "manifest.json"
                 if manifest_path.exists():
                     try:
@@ -119,18 +128,21 @@ class PluginManager:
                             plugin_id = manifest.get('id')
                             if plugin_id:
                                 plugin_ids.append(plugin_id)
-                                self.plugin_manifests[plugin_id] = manifest
+                                new_manifests[plugin_id] = manifest
-                                
+                                new_directories[plugin_id] = item
-                                # Store directory mapping
-                                if not hasattr(self, 'plugin_directories'):
-                                    self.plugin_directories = {}
-                                self.plugin_directories[plugin_id] = item
                     except (json.JSONDecodeError, PermissionError, OSError) as e:
                         self.logger.warning("Error reading manifest from %s: %s", manifest_path, e, exc_info=True)
                         continue
         except (OSError, PermissionError) as e:
             self.logger.error("Error scanning directory %s: %s", directory, e, exc_info=True)
-        
+
+        # Update shared state under lock
+        with self._discovery_lock:
+            self.plugin_manifests.update(new_manifests)
+            if not hasattr(self, 'plugin_directories'):
+                self.plugin_directories = {}
+            self.plugin_directories.update(new_directories)
+
         return plugin_ids
     
     def discover_plugins(self) -> List[str]:
@@ -459,7 +471,9 @@ class PluginManager:
         if manifest_path.exists():
             try:
                 with open(manifest_path, 'r', encoding='utf-8') as f:
-                    self.plugin_manifests[plugin_id] = json.load(f)
+                    manifest = json.load(f)
+                with self._discovery_lock:
+                    self.plugin_manifests[plugin_id] = manifest
             except Exception as e:
                 self.logger.error("Error reading manifest: %s", e, exc_info=True)
                 return False
@@ -506,10 +520,11 @@ class PluginManager:
         Returns:
             Dict with plugin information or None if not found
         """
-        manifest = self.plugin_manifests.get(plugin_id)
+        with self._discovery_lock:
+            manifest = self.plugin_manifests.get(plugin_id)
         if not manifest:
             return None
-        
+
         info = manifest.copy()
         
         # Add runtime information if plugin is loaded
@@ -533,7 +548,9 @@ class PluginManager:
         Returns:
             List of plugin info dictionaries
         """
-        return [info for info in [self.get_plugin_info(pid) for pid in self.plugin_manifests.keys()] if info]
+        with self._discovery_lock:
+            pids = list(self.plugin_manifests.keys())
+        return [info for info in [self.get_plugin_info(pid) for pid in pids] if info]
     
     def get_plugin_directory(self, plugin_id: str) -> Optional[str]:
         """
@@ -545,8 +562,9 @@ class PluginManager:
         Returns:
             Directory path as string or None if not found
         """
-        if hasattr(self, 'plugin_directories') and plugin_id in self.plugin_directories:
+        with self._discovery_lock:
-            return str(self.plugin_directories[plugin_id])
+            if hasattr(self, 'plugin_directories') and plugin_id in self.plugin_directories:
+                return str(self.plugin_directories[plugin_id])
         
         plugin_dir = self.plugins_dir / plugin_id
         if plugin_dir.exists():
@@ -568,10 +586,11 @@ class PluginManager:
         Returns:
             List of display mode names
         """
-        manifest = self.plugin_manifests.get(plugin_id)
+        with self._discovery_lock:
+            manifest = self.plugin_manifests.get(plugin_id)
         if not manifest:
             return []
-        
+
         display_modes = manifest.get('display_modes', [])
         if isinstance(display_modes, list):
             return display_modes
@@ -588,12 +607,14 @@ class PluginManager:
             Plugin identifier or None if not found.
         """
         normalized_mode = mode.strip().lower()
-        for plugin_id, manifest in self.plugin_manifests.items():
+        with self._discovery_lock:
+            manifests_snapshot = dict(self.plugin_manifests)
+        for plugin_id, manifest in manifests_snapshot.items():
             display_modes = manifest.get('display_modes')
             if isinstance(display_modes, list) and display_modes:
                 if any(m.lower() == normalized_mode for m in display_modes):
                     return plugin_id
-        
+
         return None
 
     def _get_plugin_update_interval(self, plugin_id: str, plugin_instance: Any) -> Optional[float]:

src/plugin_system/state_reconciliation.py

@@ -67,21 +67,24 @@ class StateReconciliation:
         state_manager: PluginStateManager,
         config_manager,
         plugin_manager,
-        plugins_dir: Path
+        plugins_dir: Path,
+        store_manager=None
     ):
         """
         Initialize reconciliation system.
-        
+
         Args:
             state_manager: PluginStateManager instance
             config_manager: ConfigManager instance
             plugin_manager: PluginManager instance
             plugins_dir: Path to plugins directory
+            store_manager: Optional PluginStoreManager for auto-repair
         """
         self.state_manager = state_manager
         self.config_manager = config_manager
         self.plugin_manager = plugin_manager
         self.plugins_dir = Path(plugins_dir)
+        self.store_manager = store_manager
         self.logger = get_logger(__name__)
     
     def reconcile_state(self) -> ReconciliationResult:
@@ -160,18 +163,32 @@ class StateReconciliation:
                 message=f"Reconciliation failed: {str(e)}"
             )
     
+    # Top-level config keys that are NOT plugins
+    _SYSTEM_CONFIG_KEYS = frozenset({
+        'web_display_autostart', 'timezone', 'location', 'display',
+        'plugin_system', 'vegas_scroll_speed', 'vegas_separator_width',
+        'vegas_target_fps', 'vegas_buffer_ahead', 'vegas_plugin_order',
+        'vegas_excluded_plugins', 'vegas_scroll_enabled', 'logging',
+        'dim_schedule', 'network', 'system', 'schedule',
+    })
+
     def _get_config_state(self) -> Dict[str, Dict[str, Any]]:
         """Get plugin state from config file."""
         state = {}
         try:
             config = self.config_manager.load_config()
             for plugin_id, plugin_config in config.items():
-                if isinstance(plugin_config, dict):
+                if not isinstance(plugin_config, dict):
-                    state[plugin_id] = {
+                    continue
-                        'enabled': plugin_config.get('enabled', False),
+                if plugin_id in self._SYSTEM_CONFIG_KEYS:
-                        'version': plugin_config.get('version'),
+                    continue
-                        'exists_in_config': True
+                if 'enabled' not in plugin_config:
-                    }
+                    continue
+                state[plugin_id] = {
+                    'enabled': plugin_config.get('enabled', False),
+                    'version': plugin_config.get('version'),
+                    'exists_in_config': True
+                }
         except Exception as e:
             self.logger.warning(f"Error reading config state: {e}")
         return state
@@ -184,6 +201,8 @@ class StateReconciliation:
                 for plugin_dir in self.plugins_dir.iterdir():
                     if plugin_dir.is_dir():
                         plugin_id = plugin_dir.name
+                        if '.standalone-backup-' in plugin_id:
+                            continue
                         manifest_path = plugin_dir / "manifest.json"
                         if manifest_path.exists():
                             import json
@@ -263,14 +282,15 @@ class StateReconciliation:
         
         # Check: Plugin in config but not on disk
         if config.get('exists_in_config') and not disk.get('exists_on_disk'):
+            can_repair = self.store_manager is not None
             inconsistencies.append(Inconsistency(
                 plugin_id=plugin_id,
                 inconsistency_type=InconsistencyType.PLUGIN_MISSING_ON_DISK,
                 description=f"Plugin {plugin_id} in config but not on disk",
-                fix_action=FixAction.MANUAL_FIX_REQUIRED,
+                fix_action=FixAction.AUTO_FIX if can_repair else FixAction.MANUAL_FIX_REQUIRED,
                 current_state={'exists_on_disk': False},
                 expected_state={'exists_on_disk': True},
-                can_auto_fix=False
+                can_auto_fix=can_repair
             ))
         
         # Check: Enabled state mismatch
@@ -303,6 +323,9 @@ class StateReconciliation:
                 self.logger.info(f"Fixed: Added {inconsistency.plugin_id} to config")
                 return True
             
+            elif inconsistency.inconsistency_type == InconsistencyType.PLUGIN_MISSING_ON_DISK:
+                return self._auto_repair_missing_plugin(inconsistency.plugin_id)
+
             elif inconsistency.inconsistency_type == InconsistencyType.PLUGIN_ENABLED_MISMATCH:
                 # Sync enabled state from state manager to config
                 expected_enabled = inconsistency.expected_state.get('enabled')
@@ -317,6 +340,34 @@ class StateReconciliation:
         except Exception as e:
             self.logger.error(f"Error fixing inconsistency: {e}", exc_info=True)
             return False
-        
+
+        return False
+
+    def _auto_repair_missing_plugin(self, plugin_id: str) -> bool:
+        """Attempt to reinstall a missing plugin from the store."""
+        if not self.store_manager:
+            return False
+
+        # Try the plugin_id as-is, then without 'ledmatrix-' prefix
+        candidates = [plugin_id]
+        if plugin_id.startswith('ledmatrix-'):
+            candidates.append(plugin_id[len('ledmatrix-'):])
+
+        for candidate_id in candidates:
+            try:
+                self.logger.info("[AutoRepair] Attempting to reinstall missing plugin: %s", candidate_id)
+                result = self.store_manager.install_plugin(candidate_id)
+                if isinstance(result, dict):
+                    success = result.get('success', False)
+                else:
+                    success = bool(result)
+
+                if success:
+                    self.logger.info("[AutoRepair] Successfully reinstalled plugin: %s (config key: %s)", candidate_id, plugin_id)
+                    return True
+            except Exception as e:
+                self.logger.error("[AutoRepair] Error reinstalling %s: %s", candidate_id, e, exc_info=True)
+
+        self.logger.warning("[AutoRepair] Could not reinstall %s from store", plugin_id)
         return False
 

src/plugin_system/store_manager.py

@@ -1784,6 +1784,12 @@ class PluginStoreManager:
                 # Try to get remote info from registry (optional)
                 self.fetch_registry(force_refresh=True)
                 plugin_info_remote = self.get_plugin_info(plugin_id, fetch_latest_from_github=True, force_refresh=True)
+                # Try without 'ledmatrix-' prefix (monorepo migration)
+                if not plugin_info_remote and plugin_id.startswith('ledmatrix-'):
+                    alt_id = plugin_id[len('ledmatrix-'):]
+                    plugin_info_remote = self.get_plugin_info(alt_id, fetch_latest_from_github=True, force_refresh=True)
+                    if plugin_info_remote:
+                        self.logger.info(f"Plugin {plugin_id} found in registry as {alt_id}")
                 remote_branch = None
                 remote_sha = None
 
@@ -2058,7 +2064,16 @@ class PluginStoreManager:
             self.logger.info(f"Plugin {plugin_id} is not a git repository, checking registry...")
             self.fetch_registry(force_refresh=True)
             plugin_info_remote = self.get_plugin_info(plugin_id, fetch_latest_from_github=True, force_refresh=True)
-            
+
+            # If not found, try without 'ledmatrix-' prefix (monorepo migration)
+            registry_id = plugin_id
+            if not plugin_info_remote and plugin_id.startswith('ledmatrix-'):
+                alt_id = plugin_id[len('ledmatrix-'):]
+                plugin_info_remote = self.get_plugin_info(alt_id, fetch_latest_from_github=True, force_refresh=True)
+                if plugin_info_remote:
+                    registry_id = alt_id
+                    self.logger.info(f"Plugin {plugin_id} found in registry as {alt_id}")
+
             # If not in registry but we have a repo URL, try reinstalling from that URL
             if not plugin_info_remote and repo_url:
                 self.logger.info(f"Plugin {plugin_id} not in registry but has git remote URL. Reinstalling from {repo_url} to enable updates...")
@@ -2111,13 +2126,13 @@ class PluginStoreManager:
                 self.logger.debug(f"Could not compare versions for {plugin_id}: {e}")
 
             # Plugin is not a git repo but is in registry and has a newer version - reinstall
-            self.logger.info(f"Plugin {plugin_id} not installed via git; re-installing latest archive")
+            self.logger.info(f"Plugin {plugin_id} not installed via git; re-installing latest archive (registry id: {registry_id})")
 
             # Remove directory and reinstall fresh
             if not self._safe_remove_directory(plugin_path):
                 self.logger.error(f"Failed to remove old plugin directory for {plugin_id}")
                 return False
-            return self.install_plugin(plugin_id)
+            return self.install_plugin(registry_id)
 
         except Exception as e:
             import traceback

web_interface/app.py

@@ -651,12 +651,49 @@ def _initialize_health_monitor():
     
     _health_monitor_initialized = True
 
-# Initialize health monitor on first request (using before_request for compatibility)
+_reconciliation_done = False
+_reconciliation_started = False
+
+def _run_startup_reconciliation():
+    """Run state reconciliation in background to auto-repair missing plugins."""
+    global _reconciliation_done, _reconciliation_started
+    from src.logging_config import get_logger
+    _logger = get_logger('reconciliation')
+
+    try:
+        from src.plugin_system.state_reconciliation import StateReconciliation
+        reconciler = StateReconciliation(
+            state_manager=plugin_state_manager,
+            config_manager=config_manager,
+            plugin_manager=plugin_manager,
+            plugins_dir=plugins_dir,
+            store_manager=plugin_store_manager
+        )
+        result = reconciler.reconcile_state()
+        if result.inconsistencies_found:
+            _logger.info("[Reconciliation] %s", result.message)
+        if result.reconciliation_successful:
+            if result.inconsistencies_fixed:
+                plugin_manager.discover_plugins()
+            _reconciliation_done = True
+        else:
+            _logger.warning("[Reconciliation] Finished with unresolved issues, will retry")
+            _reconciliation_started = False
+    except Exception as e:
+        _logger.error("[Reconciliation] Error: %s", e, exc_info=True)
+        _reconciliation_started = False
+
+# Initialize health monitor and run reconciliation on first request
 @app.before_request
 def check_health_monitor():
-    """Ensure health monitor is initialized on first request."""
+    """Ensure health monitor is initialized; launch reconciliation in background."""
+    global _reconciliation_started
     if not _health_monitor_initialized:
         _initialize_health_monitor()
+    if not _reconciliation_started:
+        _reconciliation_started = True
+        import threading
+        threading.Thread(target=_run_startup_reconciliation, daemon=True).start()
 
 if __name__ == '__main__':
     app.run(host='0.0.0.0', port=5000, debug=True)

web_interface/blueprints/api_v3.py

@@ -33,6 +33,29 @@ from src.web_interface.secret_helpers import (
     separate_secrets,
 )
 
+_SECRET_KEY_PATTERN = re.compile(
+    r'(api_key|api_secret|password|secret|token|auth_key|credential)',
+    re.IGNORECASE,
+)
+
+def _conservative_mask_config(config, _parent_key=None):
+    """Mask string values whose keys look like secrets (no schema available)."""
+    if isinstance(config, list):
+        return [
+            _conservative_mask_config(item, _parent_key) if isinstance(item, (dict, list))
+            else ('' if isinstance(item, str) and item and _parent_key and _SECRET_KEY_PATTERN.search(_parent_key) else item)
+            for item in config
+        ]
+    result = dict(config)
+    for key, value in result.items():
+        if isinstance(value, dict):
+            result[key] = _conservative_mask_config(value)
+        elif isinstance(value, list):
+            result[key] = _conservative_mask_config(value, key)
+        elif isinstance(value, str) and value and _SECRET_KEY_PATTERN.search(key):
+            result[key] = ''
+    return result
+
 # Will be initialized when blueprint is registered
 config_manager = None
 plugin_manager = None
@@ -2505,24 +2528,19 @@ def get_plugin_config():
             }
 
         # Mask secret fields before returning to prevent exposing API keys
-        # Fail closed — if schema unavailable, refuse to return unmasked config
         schema_mgr = api_v3.schema_manager
-        if not schema_mgr:
+        schema_for_mask = None
-            return error_response(
+        if schema_mgr:
-                ErrorCode.CONFIG_LOAD_FAILED,
+            try:
-                f"Cannot safely return config for {plugin_id}: schema manager unavailable",
+                schema_for_mask = schema_mgr.load_schema(plugin_id, use_cache=True)
-                status_code=500
+            except Exception as e:
-            )
+                logger.error("[PluginConfig] Error loading schema for %s: %s", plugin_id, e, exc_info=True)
 
-        schema_for_mask = schema_mgr.load_schema(plugin_id, use_cache=True)
+        if schema_for_mask and 'properties' in schema_for_mask:
-        if not schema_for_mask or 'properties' not in schema_for_mask:
+            plugin_config = mask_secret_fields(plugin_config, schema_for_mask['properties'])
-            return error_response(
+        else:
-                ErrorCode.CONFIG_LOAD_FAILED,
+            logger.warning("[PluginConfig] Schema unavailable for %s, applying conservative masking", plugin_id)
-                f"Cannot safely return config for {plugin_id}: schema unavailable for secret masking",
+            plugin_config = _conservative_mask_config(plugin_config)
-                status_code=500
-            )
-
-        plugin_config = mask_secret_fields(plugin_config, schema_for_mask['properties'])
 
         return success_response(data=plugin_config)
     except Exception as e: