fix(controller): sync status when traffic routing errors to allow progress deadline checks

[Goutham-Annem]

What this PR does

When reconcileTrafficRouting() returns an error — for example, when Istio delays the DestinationRule switch until the canary ReplicaSet is fully available — the controller previously returned immediately without calling syncRolloutStatusCanary(). Because syncRolloutStatusCanary() is where evaluateProgressDeadlineAbort() runs, the progress deadline could never fire while traffic routing kept failing on every reconciliation cycle.

Root cause (from issue #4626):

rolloutCanary()
  └─► reconcileTrafficRouting()  ← returns error every cycle
  └─► return err                 ← EXITS HERE
  ✗  syncRolloutStatusCanary()   ← NEVER REACHED
       └─► evaluateProgressDeadlineAbort()  ← NEVER FIRES

Fix: When reconcileTrafficRouting() fails, call syncRolloutStatusCanary() before returning the error. Status is updated on every reconciliation cycle so the deadline check always gets a chance to run.

if trafficErr := c.reconcileTrafficRouting(); trafficErr != nil {
    if syncErr := c.syncRolloutStatusCanary(); syncErr != nil {
        return syncErr
    }
    return trafficErr
}

Test coverage

• Added TestProgressDeadlineAbortWithTrafficRoutingError: creates a canary rollout with progressDeadlineAbort: true, injects an already-timed-out progressing condition, sets the mock traffic router to return an error, and verifies that verifyPatchedRolloutAborted() fires even when the traffic routing error path is taken.
• Updated two existing tests (TestReconcileTrafficRoutingSetWeightErr, TestReconcileTrafficRoutingVerifyWeightEndOfRollout, TestTrafficRoutingErrorsWhenNewCanaryHasNoReplicas) to expect the extra status patch that is now emitted on every traffic routing error.

Which issue(s) this PR fixes

Fixes #4626

Note: This PR was developed with AI assistance (Claude Code).

[codecov]

Codecov Report

✅ All modified and coverable lines are covered by tests.
✅ Project coverage is 85.04%. Comparing base (d1c2967) to head (29b4ddb).
⚠️ Report is 1 commits behind head on master.

Additional details and impacted files

@@            Coverage Diff             @@
##           master    #4826      +/-   ##
==========================================
- Coverage   85.09%   85.04%   -0.05%     
==========================================
  Files         166      166              
  Lines       19136    19139       +3     
==========================================
- Hits        16283    16277       -6     
- Misses       2005     2010       +5     
- Partials      848      852       +4     

Flag	Coverage Δ
e2e	52.78% <60.00%> (-0.20%)	⬇️
unit-tests	81.40% <100.00%> (+0.01%)	⬆️

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[github-actions]

Published E2E Test Results

  4 files    4 suites   3h 53m 25s ⏱️
122 tests 111 ✅  7 💤  4 ❌
498 runs  460 ✅ 28 💤 10 ❌

For more details on these failures, see this check.

Results for commit 29b4ddb.

♻️ This comment has been updated with latest results.

[github-actions]

Published Unit Test Results

2 518 tests   2 518 ✅  3m 23s ⏱️
  130 suites      0 💤
    1 files        0 ❌

Results for commit 29b4ddb.

♻️ This comment has been updated with latest results.

[sonarqubecloud]

Quality Gate passed

Issues
0 New issues
0 Accepted issues

Measures
0 Security Hotspots
0.0% Coverage on New Code
0.0% Duplication on New Code

See analysis details on SonarQube Cloud