fix(core): harden text-measurement caches; surface snapshot failures (#400)

* fix(core): harden text-measurement caches; surface snapshot failures

Deep-dive findings, all three latent on every 24/7 install:

- font_manager.metrics_cache and display_manager._text_width_cache were
  unbounded dicts keyed by (text, id(font)). Two problems: keys embed
  the measured TEXT, so ever-changing strings (a clock, a live score, a
  ticker) grow them without limit; and id()-keying without holding a
  reference means a garbage-collected font's id can be recycled by a
  DIFFERENT font, silently returning wrong widths/metrics (classic
  plugins create fonts per render, so this is reachable). Both caches
  are now LRU-bounded (1024) and pin the font in the entry so its id
  stays valid. metrics_cache also keyed on the text itself instead of
  hash(text), removing a collision path.

- _write_snapshot_if_due logged failures at DEBUG — invisible at the
  default level. The snapshot's mtime is the web UI's display mirror
  AND its hardware-liveness proxy, so a quiet failure freezes the
  mirror and makes health checks lie (seen in the field: a stale
  root-owned /tmp file froze it for a day). Failures now WARN, rate-
  limited to once per 5 minutes.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01FqzC1nzTWL4kaqgMaQZFam

* test: sync mock cache manager signature with CacheManager.get

test_circuit_breaker has been failing on main: plugin_health passes
memory_ttl= to cache_manager.get(), and the conftest mock's signature
was never updated — the same component/double drift class as the
monitored_update bug (#392).

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01FqzC1nzTWL4kaqgMaQZFam

---------

Co-authored-by: Chuck <chuck@example.com>
Co-authored-by: Claude Fable 5 <noreply@anthropic.com>

src/font_manager.py

@@ -35,6 +35,7 @@ import urllib.request
 import zipfile
 import tempfile
 import time
+from collections import OrderedDict
 from pathlib import Path
 from PIL import ImageFont
 from typing import Dict, Tuple, Optional, Union, Any, List
@@ -58,7 +59,13 @@ class FontManager:
         # Font discovery and catalog
         self.font_catalog: Dict[str, str] = {}  # family_name -> file_path
         self.font_cache: Dict[str, Union[ImageFont.FreeTypeFont, freetype.Face]] = {}  # (family, size) -> font
-        self.metrics_cache: Dict[str, Tuple[int, int, int]] = {}  # (text, font_id) -> (width, height, baseline)
+        # (text, id(font)) -> ((width, height, baseline), font_ref).
+        # LRU-bounded — keys embed the measured TEXT, so changing strings
+        # (clocks, live scores) would otherwise grow it forever. Entries
+        # keep the font alive so its id() can't be recycled by a different
+        # font object (which would silently return wrong metrics).
+        self.metrics_cache: "OrderedDict[Any, Tuple[Tuple[int, int, int], Any]]" = OrderedDict()
+        self._METRICS_CACHE_MAX = 1024
 
         # Plugin font management
         self.plugin_fonts: Dict[str, Dict[str, Any]] = {}  # plugin_id -> font_manifest
@@ -555,10 +562,14 @@ class FontManager:
         Returns:
             Tuple of (width, height, baseline_offset)
         """
-        cache_key = f"{hash(text)}_{id(font)}"
+        # Key on the text itself (hash(text) could collide) + font identity;
+        # the entry below keeps the font referenced so the id stays valid.
+        cache_key = (text, id(font))
 
-        if cache_key in self.metrics_cache:
-            return self.metrics_cache[cache_key]
+        cached = self.metrics_cache.get(cache_key)
+        if cached is not None:
+            self.metrics_cache.move_to_end(cache_key)
+            return cached[0]
 
         try:
             if isinstance(font, freetype.Face):
@@ -595,7 +606,9 @@ class FontManager:
             baseline = 10
 
         result = (width, height, baseline)
-        self.metrics_cache[cache_key] = result
+        self.metrics_cache[cache_key] = (result, font)
+        while len(self.metrics_cache) > self._METRICS_CACHE_MAX:
+            self.metrics_cache.popitem(last=False)
         return result
 
     def get_font_height(self, font: Union[ImageFont.FreeTypeFont, freetype.Face]) -> int: