Fix evening scheduler: NULL strength data crashed all user check-ins

Bodyweight exercises (sled pull, reverse hyper, etc.) logged with NULL
weight_lbs in strength_set. db_read.get_strength() converted str(None)
to "None", then strength.py float("None") crashed. The single try/except
in _gather_context meant the crash in _checkin discarded all context,
so has_composable_data() returned False and every user got the onboarding
"no health data" message.

Root cause: db_read.py str(None) -> "None" for NULL SQLite values.
Structural cause: _gather_context wrapped all data sources in one try block.

Fixes:
- db_read.get_strength: NULL weight/reps/rpe -> "0"/"" not "None"
- db_read.get_weights/get_bp: filter out NULL rows (defense-in-depth)
- strength.py: defensive float() with try/except
- scoring engine: _apply_clinical catches bad float values
- briefing.py: _load_weight_log/_load_bp_log skip bad rows
- scheduler.py: separate try/except per data source in _gather_context

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

Author: a-deal

engine/coaching/briefing.py

@@ -1059,7 +1059,13 @@ def _load_weight_log(data_dir: Path, person_id: str | None = None) -> Optional[l
     user_id = _user_id_from_person(person_id)
     rows = get_weights(user_id, data_dir)
     if rows:
-        return [{"weight": float(r["weight_lbs"]), "date": r["date"]} for r in rows]
+        result = []
+        for r in rows:
+            try:
+                result.append({"weight": float(r["weight_lbs"]), "date": r["date"]})
+            except (ValueError, TypeError):
+                continue
+        return result or None
     return None
 
 
@@ -1068,7 +1074,13 @@ def _load_bp_log(data_dir: Path, person_id: str | None = None) -> Optional[list]
     user_id = _user_id_from_person(person_id)
     rows = get_bp(user_id, data_dir)
     if rows:
-        return [{"sys": float(r["systolic"]), "dia": float(r["diastolic"]), "date": r.get("date", "")} for r in rows]
+        result = []
+        for r in rows:
+            try:
+                result.append({"sys": float(r["systolic"]), "dia": float(r["diastolic"]), "date": r.get("date", "")})
+            except (ValueError, TypeError):
+                continue
+        return result or None
     return None
 
 

engine/db_read.py

@@ -273,7 +273,7 @@ def get_weights(user_id: str | None = None, data_dir: Path | None = None) -> lis
         ).fetchall()
         db.close()
         if rows:
-            return [{"date": r["date"], "weight_lbs": str(r["weight_lbs"]), "source": r["source"] or ""} for r in rows]
+            return [{"date": r["date"], "weight_lbs": str(r["weight_lbs"]), "source": r["source"] or ""} for r in rows if r["weight_lbs"] is not None]
     except Exception:
         pass
     # CSV fallback (repo mode only)
@@ -296,7 +296,7 @@ def get_bp(user_id: str | None = None, data_dir: Path | None = None) -> list[dic
         ).fetchall()
         db.close()
         if rows:
-            return [{"date": r["date"], "systolic": str(r["systolic"]), "diastolic": str(r["diastolic"]), "source": r["source"] or ""} for r in rows]
+            return [{"date": r["date"], "systolic": str(r["systolic"]), "diastolic": str(r["diastolic"]), "source": r["source"] or ""} for r in rows if r["systolic"] is not None and r["diastolic"] is not None]
     except Exception:
         pass
     if data_dir:
@@ -471,7 +471,10 @@ def get_strength(user_id: str | None = None, data_dir: Path | None = None) -> li
         ).fetchall()
         db.close()
         if rows:
-            return [{"date": r["date"], "exercise": r["exercise"], "weight_lbs": str(r["weight_lbs"]), "reps": str(r["reps"]), "rpe": str(r["rpe"] or "")} for r in rows]
+            return [{"date": r["date"], "exercise": r["exercise"],
+                     "weight_lbs": str(r["weight_lbs"]) if r["weight_lbs"] is not None else "0",
+                     "reps": str(r["reps"]) if r["reps"] is not None else "0",
+                     "rpe": str(r["rpe"]) if r["rpe"] is not None else ""} for r in rows]
     except Exception:
         pass
     if data_dir:

engine/gateway/scheduler.py

@@ -595,17 +595,27 @@ def _gather_context(schedule_type: str, user_id: str) -> dict:
     from mcp_server.tools import _checkin, _score, _get_protocols
 
     context = {}
-    try:
-        if schedule_type in ("morning_brief", "evening_checkin"):
+
+    # Each data source gets its own try/except so a failure in one
+    # (e.g. _get_protocols) doesn't discard already-fetched data (e.g. checkin).
+    if schedule_type in ("morning_brief", "evening_checkin", "weekly_review"):
+        try:
             context["checkin"] = _checkin(user_id=user_id)
-        if schedule_type == "evening_checkin":
+        except Exception as e:
+            logger.warning("Failed to gather checkin for %s/%s: %s", user_id, schedule_type, e)
+            context["checkin_error"] = str(e)
+
+    if schedule_type == "evening_checkin":
+        try:
             context["protocols"] = _get_protocols(user_id=user_id)
-        if schedule_type == "weekly_review":
-            context["checkin"] = _checkin(user_id=user_id)
+        except Exception as e:
+            logger.warning("Failed to gather protocols for %s/%s: %s", user_id, schedule_type, e)
+
+    if schedule_type == "weekly_review":
+        try:
             context["score"] = _score(user_id=user_id)
-    except Exception as e:
-        logger.warning("Failed to gather context for %s/%s: %s", user_id, schedule_type, e)
-        context["error"] = str(e)
+        except Exception as e:
+            logger.warning("Failed to gather score for %s/%s: %s", user_id, schedule_type, e)
 
     return context
 

engine/scoring/engine.py

@@ -148,7 +148,11 @@ def assess(value: Optional[float], table: dict, demo: Demographics,
 def _apply_clinical(result: MetricResult, clinical_key: str, value, demo: Demographics):
     """Apply clinical zone assessment to a MetricResult."""
     if value is not None:
-        zone, note = clinical_assess(clinical_key, float(value), demo.age, demo.sex)
+        try:
+            fval = float(value)
+        except (ValueError, TypeError):
+            return
+        zone, note = clinical_assess(clinical_key, fval, demo.age, demo.sex)
         result.clinical_zone = zone
         result.clinical_note = note
 

engine/tracking/strength.py

@@ -82,9 +82,20 @@ def progression_summary(
 
     # Calculate estimated 1RM for each set
     for s in filtered:
-        weight = float(s.get("weight_lbs", 0))
-        reps = int(s.get("reps", 0) or 0)
-        rpe = float(s["rpe"]) if s.get("rpe") else None
+        try:
+            weight = float(s.get("weight_lbs") or 0)
+        except (ValueError, TypeError):
+            weight = 0
+        try:
+            reps = int(float(s.get("reps") or 0))
+        except (ValueError, TypeError):
+            reps = 0
+        rpe = None
+        if s.get("rpe"):
+            try:
+                rpe = float(s["rpe"])
+            except (ValueError, TypeError):
+                pass
         if weight > 0 and reps > 0:
             s["est_1rm"] = est_1rm(weight, reps, rpe)
         else:

tests/test_scheduler.py

@@ -725,3 +725,91 @@ def test_standalone_endpoint_calls_measure(self, mock_measure):
         data = resp.json()
         assert data["measured_count"] == 1
         mock_measure.assert_called_once()
+
+
+# --- _gather_context isolation tests ---
+
+
+class TestGatherContextIsolation:
+    """Verify that _gather_context uses separate try/except blocks so a
+    failure in one data source doesn't discard already-fetched data."""
+
+    def test_checkin_failure_sets_error_key(self):
+        """If _checkin throws, context should have checkin_error but no checkin."""
+        from engine.gateway.scheduler import _gather_context
+
+        with patch("mcp_server.tools._checkin", side_effect=ValueError("could not convert string to float: 'None'")):
+            ctx = _gather_context("morning_brief", "andrew")
+
+        assert "checkin" not in ctx
+        assert "checkin_error" in ctx
+        assert "'None'" in ctx["checkin_error"]
+
+    def test_protocols_failure_preserves_checkin(self):
+        """If _get_protocols throws, the already-fetched checkin should survive."""
+        from engine.gateway.scheduler import _gather_context
+
+        fake_checkin = {"data_available": {"garmin": True}, "score": {"coverage": 6}}
+        with patch("mcp_server.tools._checkin", return_value=fake_checkin), \
+             patch("mcp_server.tools._get_protocols", side_effect=Exception("db locked")):
+            ctx = _gather_context("evening_checkin", "andrew")
+
+        assert ctx["checkin"] == fake_checkin
+        assert "protocols" not in ctx
+
+    def test_score_failure_preserves_checkin_for_weekly(self):
+        """If _score throws during weekly_review, checkin should survive."""
+        from engine.gateway.scheduler import _gather_context
+
+        fake_checkin = {"data_available": {"garmin": True}, "score": {"coverage": 6}}
+        with patch("mcp_server.tools._checkin", return_value=fake_checkin), \
+             patch("mcp_server.tools._score", side_effect=Exception("timeout")):
+            ctx = _gather_context("weekly_review", "andrew")
+
+        assert ctx["checkin"] == fake_checkin
+        assert "score" not in ctx
+
+
+# --- db_read NULL handling tests ---
+
+
+class TestStrengthNoneHandling:
+    """Verify that strength.py handles 'None' string values from db_read
+    without crashing. This was the root cause of the evening scheduler bug:
+    bodyweight exercises have NULL weight_lbs in SQLite, db_read.get_strength
+    converted str(None) -> 'None', then float('None') crashed."""
+
+    def test_progression_handles_none_string_weight(self):
+        """progression_summary should not crash on 'None' weight_lbs."""
+        from engine.tracking.strength import progression_summary
+
+        lift_history = [
+            {"date": "2026-04-04", "exercise": "Squat", "weight_lbs": "315", "reps": "5", "rpe": "8"},
+            {"date": "2026-04-04", "exercise": "Squat", "weight_lbs": "None", "reps": "None", "rpe": ""},
+            {"date": "2026-04-04", "exercise": "Squat", "weight_lbs": "0", "reps": "0", "rpe": ""},
+        ]
+        result = progression_summary(lift_history, "Squat")
+        assert result is not None
+        assert result["peak_1rm"] > 0
+
+    def test_progression_handles_none_reps(self):
+        """progression_summary should not crash on 'None' reps."""
+        from engine.tracking.strength import progression_summary
+
+        lift_history = [
+            {"date": "2026-04-04", "exercise": "Sled Pull", "weight_lbs": "None", "reps": "None", "rpe": "None"},
+        ]
+        result = progression_summary(lift_history, "Sled Pull")
+        assert result is not None
+
+    def test_clinical_assess_handles_none_string(self):
+        """_apply_clinical should not crash on string 'None' values."""
+        from engine.scoring.engine import _apply_clinical
+        from engine.models import Demographics, MetricResult
+
+        demo = Demographics(age=35, sex="M")
+        result = MetricResult(name="rhr", tier=1, rank=1, has_data=True)
+        # Should not raise - the string "None" should be caught
+        _apply_clinical(result, "rhr", "None", demo)
+        # clinical_zone should remain at its default (empty string), not crash
+        assert result.clinical_zone == ""