fix(desktop): avoid unhandled launchd readiness rejection (#572)

* fix(desktop): avoid unhandled launchd readiness rejection

* fix(desktop): handle attach readiness and test contract

Author: nettee

apps/desktop/main/index.ts

@@ -599,7 +599,13 @@ async function runLaunchdColdStart(): Promise<void> {
     diagnosticsReporter?.markColdStartRunning(
       "waiting for controller readiness",
     );
-    await launchdResult.controllerReady;
+  }
+
+  const controllerReady = await launchdResult.controllerReady;
+  if (!controllerReady.ok) {
+    throw controllerReady.error;
+  }
+  if (!launchdResult.isAttach) {
     logColdStart("controller ready");
   }
 

apps/desktop/main/services/launchd-bootstrap.ts

@@ -83,8 +83,8 @@ export interface LaunchdBootstrapResult {
     controller: string;
     openclaw: string;
   };
-  /** Promise that resolves when controller is ready (for optional awaiting) */
-  controllerReady: Promise<void>;
+  /** Promise that always settles with controller readiness outcome. */
+  controllerReady: Promise<ControllerReadyResult>;
   /** Actual ports used (may differ from requested if OS-assigned or recovered) */
   effectivePorts: {
     controllerPort: number;
@@ -95,6 +95,8 @@ export interface LaunchdBootstrapResult {
   isAttach: boolean;
 }
 
+type ControllerReadyResult = { ok: true } | { ok: false; error: Error };
+
 /** Metadata persisted between sessions for attach discovery */
 interface RuntimePortsMetadata {
   writtenAt: string;
@@ -595,11 +597,20 @@ export async function bootstrapWithLaunchd(
   );
 
   // Controller readiness
-  const controllerReady = needsControllerReady
-    ? waitForControllerReadiness(effectivePorts.controllerPort).then(() =>
-        console.log("Controller is ready"),
-      )
-    : Promise.resolve();
+  const controllerReady: Promise<ControllerReadyResult> = needsControllerReady
+    ? waitForControllerReadiness(effectivePorts.controllerPort)
+        .then(() => {
+          console.log("Controller is ready");
+          return { ok: true } as const;
+        })
+        .catch((error: unknown) => ({
+          ok: false,
+          error:
+            error instanceof Error
+              ? error
+              : new Error(`Controller readiness failed: ${String(error)}`),
+        }))
+    : Promise.resolve({ ok: true });
 
   // Persist port metadata
   await writeRuntimePorts(plistDir, {

tests/desktop/launchd-startup-scenarios.test.ts

@@ -807,7 +807,7 @@ describe("Launchd Startup Scenarios", () => {
     const result = await bootstrapWithLaunchd(makeBootstrapEnv() as never);
 
     // controllerReady should be a promise that resolves (fetch mock returns 200)
-    await expect(result.controllerReady).resolves.toBeUndefined();
+    await expect(result.controllerReady).resolves.toEqual({ ok: true });
   });
 
   // -----------------------------------------------------------------------
@@ -831,7 +831,7 @@ describe("Launchd Startup Scenarios", () => {
     const result = await bootstrapWithLaunchd(makeBootstrapEnv() as never);
 
     // controllerReady should resolve immediately (already healthy)
-    await expect(result.controllerReady).resolves.toBeUndefined();
+    await expect(result.controllerReady).resolves.toEqual({ ok: true });
     expect(result.isAttach).toBe(true);
   });