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libfreemkv/src/disc/read_error.rs
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//! Single source of truth for what to do when a sector read fails.
//!
//! Both Pass 1 (`Disc::sweep`) and Pass 2-N (`Disc::patch`) call into
//! `handle_read_error` after every failed `read_sectors`. The handler
//! classifies the error, updates the in-flight context (counters,
//! damage window, retry budgets), and returns a `ReadAction` the caller
//! dispatches on. Every read goes through the same gate — no path can
//! silently skip pause/skip/jump/abort logic.
//!
//! Adding a new error class = add one arm in `handle_read_error`.
//! Adding new logging on errors = one place.
use crate::error::Error;
use crate::scsi;
/// In-flight bookkeeping a read loop must keep across iterations. The
/// handler reads and mutates this. Caller owns the storage.
pub struct ReadCtx {
/// Number of sectors per read attempt. The handler uses this to
/// decide whether to bisect (only worthwhile when batch > 1).
pub batch: u16,
/// Successful reads since the last failure. Resets to 0 on failure.
/// Used by callers to drive damage-zone exit / speed restoration.
pub consecutive_good: u64,
/// Failed reads since the last success. Resets to 0 on success.
/// Drives long-pause escalation on persistent failure.
pub consecutive_failures: u64,
/// Failed OUTER batch reads since the last outer success — bisect
/// inner-sector failures are NOT counted here. Drives the
/// fast-entry damage-jump on Pass 1 (skip the disc-level grind
/// once we're clearly in a damaged region; Pass N will recover
/// the actual sectors). Reset on outer success.
pub consecutive_outer_failures: u64,
/// Sliding window of recent read outcomes (true=ok, false=fail).
/// Capped at `damage_window_max`. Drives damage-jump decisions.
pub damage_window: Vec<bool>,
pub damage_window_max: usize,
pub damage_threshold_pct: usize,
/// Trigger a damage-jump after this many consecutive outer-batch
/// failures, even when the damage_window isn't full yet. Pass 1
/// uses a small value (4) so we don't spend ~40 minutes grinding
/// to fill a 16-block window before the first jump on a damage
/// zone we entered cleanly. Pass N uses a larger value (or
/// disables this — see `bisect_on_marginal`) because Pass N's
/// whole job IS to grind on the bad ranges.
pub fast_jump_threshold: u64,
/// Multiplier applied to damage-jump distance. Doubles each jump,
/// resets to 1 after `damage_window_max` consecutive good reads.
pub jump_multiplier: u64,
/// NOT_READY retries used so far for the current LBA. Reset to 0
/// on any non-NOT_READY response.
pub not_ready_retries: u32,
/// Bridge-degradation cooldowns used so far.
pub bridge_degradation_count: u32,
/// Whether we're currently inside a damage-jump bisect attempt.
/// Caller sets this true when entering single-sector mode for a
/// failed batch, so the handler doesn't recursively request another
/// bisect on the inner-sector failures.
pub bisecting: bool,
/// Whether to return `Bisect` on a marginal-media batch failure.
/// Pass 1 sweep sets this false: a failed batch becomes
/// SkipBlock (mark the whole 32-sector ECC block NonTrimmed,
/// advance, let Pass N recover the salvageable sectors with
/// proper recovery semantics). Pass N sets this true: bisection
/// is its core job, and it has the right tools (single-sector
/// reads, 60s recovery timeout, retry budget, escalating skip).
pub bisect_on_marginal: bool,
/// Count of consecutive firmware-wedge responses (HARDWARE_ERROR
/// or ILLEGAL_REQUEST sense keys) since the last successful read.
/// Pass 1 uses this to drive the wedge-skip path: each wedge
/// triggers a 1 GB jump + cooldown pause. Reaching
/// `WEDGE_ABORT_THRESHOLD` consecutive wedges with no good read
/// in between → real AbortPass.
pub wedge_count: u64,
// ── Diagnostic counters (added 2026-05-10) ──
//
// Aggregate state for post-mortem analysis of wedge incidents.
// Every Pass 1 / Pass N sweep now produces a structured summary
// at the WARN log on each error AND an end-of-pass INFO summary.
// Goal: when a wedge happens, the operator should be able to tell
// from the logs whether it was triggered by ONE read at a
// physically-damaged sector (immediate failure) or by accumulated
// exposure across MANY reads (firmware-state buildup), and what
// the timing pattern looked like.
/// `Instant` of the most recent successful read. Used to compute
/// "time since last good" for the WARN log on each error. None
/// before the first successful read.
pub last_success_at: Option<std::time::Instant>,
/// `Instant` of the most recent failed read. Used to compute
/// "time since last error" for the WARN log. None before the
/// first error.
pub last_error_at: Option<std::time::Instant>,
/// Last error's sense-key "family" (Medium / Hardware / IllegalRequest
/// / NotReady / Other). Used to detect WEDGE TRANSITIONS — when
/// the family changes from Medium → Hardware/IllegalRequest, the
/// drive almost certainly just entered fast-fail mode. That
/// transition gets its own WARN log so the trace is unambiguous.
pub last_error_family: Option<SenseFamily>,
/// Sum of all errors observed during this sweep. Reported in the
/// end-of-pass summary.
pub total_errors: u64,
/// Sum of all successful reads during this sweep.
pub total_reads_ok: u64,
/// Count of damage zones entered (transitions from clean → in-damage).
pub zones_entered: u64,
/// Count of damage-jumps executed during this sweep.
pub jumps_taken: u64,
/// True between "first error after a clean period" and "16 consecutive
/// good reads after the last error in the cluster." Used to count
/// zone entries and to bound zone_reads accurately.
pub in_damage_zone: bool,
}
/// Coarse classification of a SCSI sense key for diagnostic logging.
/// Wedge-family events (Hardware + IllegalRequest) get their own
/// transition log when the sense family changes.
#[derive(Debug, Clone, Copy, PartialEq, Eq)]
pub enum SenseFamily {
NotReady,
Medium,
Hardware,
IllegalRequest,
Other,
}
impl SenseFamily {
pub fn from_sense_key(sense_key: u8) -> Self {
match sense_key {
scsi::SENSE_KEY_NOT_READY => SenseFamily::NotReady,
scsi::SENSE_KEY_MEDIUM_ERROR => SenseFamily::Medium,
scsi::SENSE_KEY_HARDWARE_ERROR => SenseFamily::Hardware,
scsi::SENSE_KEY_ILLEGAL_REQUEST => SenseFamily::IllegalRequest,
_ => SenseFamily::Other,
}
}
/// True for the "wedge family" — Hardware + IllegalRequest are
/// the senses the BU40N firmware returns in its fast-fail state.
pub fn is_wedge_family(self) -> bool {
matches!(self, SenseFamily::Hardware | SenseFamily::IllegalRequest)
}
}
impl ReadCtx {
/// Initial context for a Pass 1 sweep. The job is "fast and
/// accurate, get the most data in the shortest time" — Pass N
/// is the one that grinds on the bad ranges. So bisect-on-
/// marginal is OFF (failed batches become SkipBlock; whole 32-
/// sector blocks marked NonTrimmed for Pass N to revisit), and
/// the damage-jump fast-path triggers after just 1 consecutive
/// outer-batch failure — the user's wedge-prevention principle
/// (2026-05-11): once the drive returns ANY recoverable error,
/// retrying the same LBA quickly is what triggers the firmware
/// fast-fail transition. Jump immediately, never retry in Pass 1.
/// Pass N owns retries — it gets per-sector timeouts that don't
/// hammer the firmware the same way.
pub fn for_sweep(batch: u16) -> Self {
Self {
batch,
consecutive_good: 0,
consecutive_failures: 0,
consecutive_outer_failures: 0,
damage_window: Vec::with_capacity(16),
damage_window_max: 16,
damage_threshold_pct: 12,
fast_jump_threshold: 1,
jump_multiplier: 1,
not_ready_retries: 0,
bridge_degradation_count: 0,
bisecting: false,
bisect_on_marginal: false,
wedge_count: 0,
last_success_at: None,
last_error_at: None,
last_error_family: None,
total_errors: 0,
total_reads_ok: 0,
zones_entered: 0,
jumps_taken: 0,
in_damage_zone: false,
}
}
/// Initial context for a Pass 2-N patch. Pass N's whole reason to
/// exist is to recover sectors Pass 1 skipped — bisection on
/// marginal media is part of the job, and the fast-jump
/// threshold is loose so we don't bail too early on a range that
/// has scattered good sectors mixed in.
pub fn for_patch(batch: u16) -> Self {
Self {
batch,
consecutive_good: 0,
consecutive_failures: 0,
consecutive_outer_failures: 0,
damage_window: Vec::with_capacity(16),
damage_window_max: 16,
damage_threshold_pct: 12,
// Pass N is allowed to grind: window-based jump only,
// matching the historical behaviour for patch passes.
fast_jump_threshold: u64::MAX,
jump_multiplier: 1,
not_ready_retries: 0,
bridge_degradation_count: 0,
bisecting: false,
bisect_on_marginal: true,
wedge_count: 0,
last_success_at: None,
last_error_at: None,
last_error_family: None,
total_errors: 0,
total_reads_ok: 0,
zones_entered: 0,
jumps_taken: 0,
in_damage_zone: false,
}
}
/// Caller calls this after every successful read.
pub fn on_success(&mut self) {
self.consecutive_good += 1;
self.consecutive_failures = 0;
self.not_ready_retries = 0;
// Any successful read clears the wedge-skip counter — the
// drive recovered, so further wedges should reset the skip
// budget instead of accumulating toward a real abort.
self.wedge_count = 0;
// Outer-success only: a good single-sector read inside a
// bisect doesn't mean we've left the damaged batch. Only an
// outer-batch success resets the outer-failure counter.
if !self.bisecting {
self.consecutive_outer_failures = 0;
}
self.damage_window.push(true);
if self.damage_window.len() > self.damage_window_max {
self.damage_window.remove(0);
}
// Diagnostic state.
self.total_reads_ok += 1;
self.last_success_at = Some(std::time::Instant::now());
// If we were in a damage zone and accumulated enough good
// reads to exit (damage_window now all-good), the zone is
// over. Don't reset zones_entered — that's a sweep total.
if self.in_damage_zone && self.consecutive_good >= self.damage_window_max as u64 {
self.in_damage_zone = false;
self.last_error_family = None;
}
}
/// Final per-pass summary suitable for an INFO log at the end of
/// `sweep` / `patch`. Caller renders this to a single structured
/// log line.
pub fn pass_summary(&self) -> PassSummary {
PassSummary {
total_reads_ok: self.total_reads_ok,
total_errors: self.total_errors,
zones_entered: self.zones_entered,
jumps_taken: self.jumps_taken,
}
}
}
/// End-of-pass stats logged at INFO for post-mortem analysis. Lets
/// an operator answer "how damaged is this disc?" from a single log
/// line per pass.
#[derive(Debug, Clone, Copy)]
pub struct PassSummary {
pub total_reads_ok: u64,
pub total_errors: u64,
pub zones_entered: u64,
pub jumps_taken: u64,
}
/// What the caller should do after a read failure. The caller owns the
/// I/O side-effects (sleep, write zeros, advance pos) — the handler
/// only decides which side-effects.
#[derive(Debug, Clone, PartialEq, Eq)]
pub enum ReadAction {
/// Pause `pause_secs` then retry the same LBA / batch. Used for
/// transient conditions (NOT_READY, bridge degradation) that the
/// drive may recover from on its own.
Retry { pause_secs: u64 },
/// Re-issue the failed batch as `batch` single-sector reads. Each
/// inner read is itself dispatched through `handle_read_error` with
/// `bisecting = true` so it cannot recurse.
Bisect,
/// Mark the failed range NonTrimmed (zero-fill, retry in Pass N+),
/// then pause `pause_secs` before resuming the next LBA.
SkipBlock { pause_secs: u64 },
/// Mark the failed range NonTrimmed AND advance position by
/// `sectors` (zero-filling the gap as NonTrimmed). Then pause
/// `pause_secs`. Used when the damage-window threshold is crossed.
JumpAhead { sectors: u64, pause_secs: u64 },
/// Unrecoverable at this layer. Caller propagates `Err` up to the
/// outer pass loop / autorip, which can attempt USB re-enumeration,
/// drop session, etc.
AbortPass,
}
// Pause budget constants. Tuned from 2026-05-07 BU40N traces showing
// bridge wedges 524 ms after a 5.4-second internal ECC retry. The
// post-failure pauses give the drive — and the bridge — time to settle.
/// Pause between a failed read and the next read attempt — applied
/// uniformly to Pass 1 sweep and Pass N patch.
///
/// 2026-05-11 reframe: a failed read is a failed read, regardless of
/// which pass is running. The prior split (1s for Pass N, 5s for Pass
/// 1 via `PASS_1_FAIL_PAUSE_SECS`) was solving an imaginary cost
/// problem — real damaged-disc cases mark <50 MB NonTrimmed, and the
/// extra 5s/error is single-digit minutes per pass, not hours. The
/// cost of NOT pausing — a drive wedge that aborts the entire
/// multi-pass recovery — is much worse.
///
/// The wedge avoidance principle: error → drive ECC retry (5-10s
/// internal) → return → cooldown pause → next read. Same shape
/// everywhere reads can fail.
const FAIL_PAUSE_SECS: u64 = 5;
/// Long cooldown applied when a damage zone is first entered (the
/// FIRST read failure after a clean run, before the drive has had a
/// chance to cycle in retries that push it toward fast-fail).
///
/// Empirical: 2026-05-11 Dune Pt 2 wedge incident showed 7 medium
/// errors in 6.5 seconds (~1s per attempt + ~1s pause) push the
/// BU40N's firmware into IllegalRequest fast-fail mode permanently.
/// Once there, only physical eject + reload clears it. Giving the
/// drive 30s of breathing room after the FIRST error in a zone —
/// before we start adding more error counts in the firmware's
/// internal window — prevents the transition.
///
/// Cost on clean discs: zero (first-error path doesn't trigger).
/// Cost on damaged discs: ~30s × N damage zones; on a 5-zone disc
/// that's 2.5 min extra. Trade for never wedging the drive.
const ZONE_ENTRY_COOLDOWN_SECS: u64 = 30;
/// Cooldown when a long streak of failures suggests the drive is
/// stuck in a damage zone and needs MORE breathing room than the
/// standard inter-error pause. Same value as `FAIL_PAUSE_SECS`
/// because empirically 5s is enough; kept as a separate name so the
/// escalation policy is explicit at the call site.
const CONSECUTIVE_FAIL_LONG_PAUSE_SECS: u64 = 5;
const CONSECUTIVE_FAIL_LONG_PAUSE_THRESHOLD: u64 = 10;
const POST_JUMP_EXTRA_PAUSE_SECS: u64 = 2;
const NOT_READY_PAUSE_SECS: u64 = 3;
const NOT_READY_MAX_RETRIES: u32 = 3;
const BRIDGE_DEGRADATION_PAUSE_SECS: u64 = 15;
const BRIDGE_DEGRADATION_MAX_RETRIES: u32 = 5;
/// Base of the damage-jump distance formula: `jump_sectors =
/// JUMP_BASE_SECTORS × batch × jump_multiplier`. Bumped 2026-05-10
/// from 256 → 1024 (4×) so the first damage-jump at batch=32 covers
/// 64 MB instead of 16 MB. Empirically the BU40N's damage clusters
/// are 100+ MB wide; 16 MB jumps landed inside the cluster and the
/// re-read added to the firmware wedge counter. 64 MB → 128 MB
/// (after one doubling) clears almost any single-cluster damage in
/// 2 jumps.
const JUMP_BASE_SECTORS: u64 = 1024;
// Firmware-wedge skip policy for Pass 1 sweep
// ===========================================
//
// When the BU40N (or similar drives) hits a physical-damage cluster,
// its firmware can transition into a "wedge" state where it returns
// HARDWARE_ERROR or ILLEGAL_REQUEST for every subsequent read —
// often for many LBAs after the actual bad sector. Per CLAUDE.md
// "Bad-sector handling" rule #2: "Recovery requires eject+reload OR
// significant cool-down."
//
// Pass 1's pre-fix behavior was to immediately AbortPass on the
// first HARDWARE_ERROR / ILLEGAL_REQUEST, killing the rip at
// whatever percentage it had reached. That's the wrong call when:
// - the damage zone may be small (jumping past it could resume
// normal reads), AND
// - even if the drive stays wedged, finishing the sweep gives us
// an honest mapfile for Pass N to attack later.
//
// New policy: treat wedge sense codes the same way the damage-window
// treats persistent failure — JumpAhead by a large distance with a
// cooldown pause. Allow up to WEDGE_ABORT_THRESHOLD consecutive
// wedges (no successful read in between) before declaring the drive
// truly stuck and surfacing AbortPass to autorip.
/// One-gigabyte jump (1024 MiB) on each wedge. Big enough to clear
/// almost any single-cluster damage zone we've seen.
const WEDGE_JUMP_SECTORS: u64 = 524_288;
/// Cooldown pause after each wedge. Per CLAUDE.md the drive needs
/// "significant cool-down"; 30 s strikes a balance between giving
/// the drive a chance to recover and not stalling the rip if the
/// drive is permanently stuck.
const WEDGE_PAUSE_SECS: u64 = 30;
/// Bail after this many consecutive wedges with no good read in
/// between. At 1 GB jumps this lets us scan ~16 GB worth of fully
/// wedged area before giving up — generous enough to clear most
/// physical-damage clusters, bounded enough to not loop forever on
/// a permanently bricked drive.
const WEDGE_ABORT_THRESHOLD: u64 = 16;
/// Pass-N wedge-skip distance. Pass N's batch=1 reads target
/// specific NonTrimmed sectors from Pass 1, so a big 1 GB skip
/// would blow past the current NonTrimmed range and abandon many
/// sectors that might still recover. Use a smaller skip just to
/// move past the bricked LBA + a small buffer — the outer patch
/// loop's next iteration picks up the next sector in the same or
/// next range.
const WEDGE_PASS_N_SKIP_SECTORS: u64 = 64;
/// THE single error-handling entry point. Updates `ctx`, returns the
/// action the caller must apply.
///
/// New error class = add a new arm here. New logging on errors = add
/// it once at the top. New retry policy = adjust the constants. No
/// other read site needs to change.
pub fn handle_read_error(err: &Error, ctx: &mut ReadCtx) -> ReadAction {
ctx.consecutive_failures += 1;
ctx.consecutive_good = 0;
// Outer-failure counter — only OUTER batch failures count toward
// the fast-jump trigger. Bisect inner failures are part of
// recovering an already-failed batch and don't represent
// independent damage signal.
if !ctx.bisecting {
ctx.consecutive_outer_failures += 1;
}
// Diagnostic instrumentation — compute timing context BEFORE
// mutating the timestamps so the log reflects the gap to the
// PREVIOUS error / success, not zero.
let now = std::time::Instant::now();
let ms_since_last_error = ctx
.last_error_at
.map(|t| now.duration_since(t).as_millis() as u64);
let ms_since_last_success = ctx
.last_success_at
.map(|t| now.duration_since(t).as_millis() as u64);
let current_family = err
.scsi_sense()
.map(|s| SenseFamily::from_sense_key(s.sense_key))
.unwrap_or(SenseFamily::Other);
// Zone-entry tracking: this is the first error after a clean run
// (or the first error of the sweep).
if !ctx.in_damage_zone && !ctx.bisecting {
ctx.in_damage_zone = true;
ctx.zones_entered += 1;
}
ctx.total_errors += 1;
ctx.last_error_at = Some(now);
// Wedge transition: previous error was MEDIUM, this one is
// HARDWARE or ILLEGAL_REQUEST. That's the moment the drive's
// firmware flipped into fast-fail mode. Distinct WARN so logs
// make it unambiguous when the wedge "started."
let is_wedge_transition = matches!(ctx.last_error_family, Some(prev) if !prev.is_wedge_family())
&& current_family.is_wedge_family();
ctx.last_error_family = Some(current_family);
tracing::warn!(
target: "freemkv::disc",
phase = "read_error",
consecutive_failures = ctx.consecutive_failures,
consecutive_outer_failures = ctx.consecutive_outer_failures,
ms_since_last_error,
ms_since_last_success,
total_errors = ctx.total_errors,
total_reads_ok = ctx.total_reads_ok,
batch = ctx.batch,
bisecting = ctx.bisecting,
wedge_count = ctx.wedge_count,
sense_family = ?current_family,
sense_key = err.scsi_sense().map(|s| s.sense_key),
asc = err.scsi_sense().map(|s| s.asc),
ascq = err.scsi_sense().map(|s| s.ascq),
error = %err,
"read failed; classifying"
);
if is_wedge_transition {
tracing::warn!(
target: "freemkv::disc",
phase = "wedge_transition",
errors_in_zone = ctx.total_errors,
ms_since_last_success,
new_family = ?current_family,
"drive entered wedge / fast-fail family (was returning recoverable medium errors before this)"
);
}
// 1. Transport failure: bridge crash / USB disconnect. The outer
// pass loop knows how to handle this (rediscover sg path,
// re-open drive). Inline single-sector retry here was tried in
// pre-v0.17.0 builds and observed to make wedges worse.
if err.is_scsi_transport_failure() {
return ReadAction::AbortPass;
}
// 2. Bridge degradation: NOT_READY with the well-known signature
// (sense_key=2, ASC=0x04, ASCQ=0x3E). Drive's bridge is in a
// semi-stuck state but typically recovers after a long cooldown.
// If we've exhausted our retry budget, fall through to the
// marginal/skip path below.
if err.is_bridge_degradation() && ctx.bridge_degradation_count < BRIDGE_DEGRADATION_MAX_RETRIES
{
ctx.bridge_degradation_count += 1;
return ReadAction::Retry {
pause_secs: BRIDGE_DEGRADATION_PAUSE_SECS,
};
}
let sense_key = err.scsi_sense().map(|s| s.sense_key).unwrap_or(0);
// 3. Generic NOT_READY (other ASC codes): drive's mechanical
// pickup may be moving. Pause and retry briefly.
if sense_key == scsi::SENSE_KEY_NOT_READY && ctx.not_ready_retries < NOT_READY_MAX_RETRIES {
ctx.not_ready_retries += 1;
return ReadAction::Retry {
pause_secs: NOT_READY_PAUSE_SECS,
};
}
if sense_key != scsi::SENSE_KEY_NOT_READY {
ctx.not_ready_retries = 0;
}
// 4. Hardware error / illegal request — the firmware-wedge family.
// The drive transitioned into a fast-fail state where it
// rejects reads near the LBA. Same response shape for both
// passes (2026-05-11 reframe — error handling is centralized,
// and the wedge is a code-induced state we can avoid via
// pacing + skip):
//
// - Pass 1 sweep (bisect_on_marginal=false): jump
// WEDGE_JUMP_SECTORS (1 GB) ahead, pause WEDGE_PAUSE_SECS,
// mark skipped region NonTrimmed.
// - Pass N patch (bisect_on_marginal=true): give up on the
// current sector (the granular target), pause for cooldown,
// let the outer patch loop move to the next NonTrimmed
// range. Implemented as a small JumpAhead so the same code
// path serves both — Pass N's batch=1 means JumpAhead by
// WEDGE_PASS_N_SKIP_SECTORS effectively skips just this
// sector and a small buffer (gives the drive room to
// recover before the next per-sector attempt).
//
// Both paths share the WEDGE_ABORT_THRESHOLD budget — only
// AbortPass after N consecutive wedges with no successful
// read in between.
if sense_key == scsi::SENSE_KEY_HARDWARE_ERROR || sense_key == scsi::SENSE_KEY_ILLEGAL_REQUEST {
if !ctx.bisecting {
ctx.wedge_count += 1;
}
if ctx.wedge_count >= WEDGE_ABORT_THRESHOLD {
tracing::warn!(
target: "freemkv::disc",
phase = "wedge_abort",
wedge_count = ctx.wedge_count,
threshold = WEDGE_ABORT_THRESHOLD,
pass = if ctx.bisect_on_marginal { "N" } else { "1" },
"wedge-skip exhausted — drive appears permanently stuck"
);
return ReadAction::AbortPass;
}
let jump_sectors = if ctx.bisect_on_marginal {
WEDGE_PASS_N_SKIP_SECTORS
} else {
WEDGE_JUMP_SECTORS
};
tracing::warn!(
target: "freemkv::disc",
phase = "wedge_skip",
pass = if ctx.bisect_on_marginal { "N" } else { "1" },
wedge_count = ctx.wedge_count,
jump_sectors,
pause_secs = WEDGE_PAUSE_SECS,
"wedge detected — skipping ahead and pausing for drive cooldown"
);
ctx.jumps_taken += 1;
return ReadAction::JumpAhead {
sectors: jump_sectors,
pause_secs: WEDGE_PAUSE_SECS,
};
}
// 5. Marginal media (MEDIUM_ERROR / ABORTED_COMMAND) on a multi-
// sector batch: the drive can often read the same sectors
// individually. Bisect into single-sector reads (gentler on the
// bridge too — shorter SCSI transactions). Avoid recursive
// bisect.
//
// Pass 1 sweep sets `bisect_on_marginal=false` to skip this:
// its job is "fast and accurate, get the most data in the
// shortest time." Pass N is purpose-built to recover
// individual sectors with proper recovery semantics, and Pass
// 1 grinding through 32-sector bisects costs ~2.5 min per bad
// block AND fills the damage window slower than it should.
// Whole-block NonTrimmed → SkipBlock → advance → Pass N
// revisits.
let is_marginal = matches!(
sense_key,
scsi::SENSE_KEY_MEDIUM_ERROR | scsi::SENSE_KEY_ABORTED_COMMAND
);
if is_marginal && ctx.batch > 1 && !ctx.bisecting && ctx.bisect_on_marginal {
return ReadAction::Bisect;
}
// 6. Single-sector failure or unbisectable error — record in
// damage window, decide between skip-in-place vs damage-jump.
//
// SKIP damage-window updates while bisecting: the window
// represents per-batch outcomes, not per-sector. Updating it
// inside a bisect inner loop (potentially 32+ sector failures
// per batch) would over-weight the window and cause runaway
// JumpAhead distance via excessive multiplier doublings.
if !ctx.bisecting {
ctx.damage_window.push(false);
if ctx.damage_window.len() > ctx.damage_window_max {
ctx.damage_window.remove(0);
}
}
let bad_count = ctx.damage_window.iter().filter(|&&b| !b).count();
let bad_pct = if ctx.damage_window.is_empty() {
0
} else {
bad_count * 100 / ctx.damage_window.len()
};
// Inter-error pause — wedge prevention via pacing.
//
// Zone-entry case (first error after a clean run): apply the
// long ZONE_ENTRY_COOLDOWN_SECS pause. The empirical wedge
// observed 2026-05-11 happened ~7 errors into a damage zone,
// each retry adding to the firmware's internal counter. A 30s
// pause at zone entry lets the drive's bridge / firmware
// counters reset before we issue the next read.
//
// Subsequent errors in the same zone: the standard 5s pause.
// (We've already jumped past the initial damage; further errors
// mean we landed in another bad cluster — same pacing applies.)
//
// Long-streak escalation: same 5s currently; kept as a separate
// branch for future tuning. Pass N (bisect_on_marginal=true)
// uses the standard pauses — it's running single-sector retries
// on already-known-bad LBAs by design.
let is_zone_entry =
ctx.consecutive_outer_failures == 1 && !ctx.bisecting && !ctx.bisect_on_marginal;
let pause_secs = if is_zone_entry {
ZONE_ENTRY_COOLDOWN_SECS
} else if ctx.consecutive_failures >= CONSECUTIVE_FAIL_LONG_PAUSE_THRESHOLD {
CONSECUTIVE_FAIL_LONG_PAUSE_SECS
} else {
FAIL_PAUSE_SECS
};
// 7. Damage-jump: too many failures → skip ahead by an escalating
// gap. Multiplier capped so we can't accidentally skip the
// entire rest of the disc (observed 2026-05-07: a saturated
// multiplier produced a 56 GB jump). Saturating arithmetic on
// the sector calc as defence in depth.
//
// Jump base bumped 2026-05-10 from 256 to 1024 sectors per
// multiplier unit (= 64 MB first jump at batch=32, up from
// 16 MB). The smaller base routinely landed jumps back inside
// damage clusters of 100+ MB, each landing adding to the
// firmware's wedge counter. 64 MB initial + 128 MB second +
// 256 MB third clears almost any single-cluster damage
// pattern we've seen in 2 jumps.
//
// Two triggers, evaluated in order:
//
// a. **Fast-entry** — `consecutive_outer_failures >= fast_jump_threshold`.
// Fires on Pass 1 (threshold=4) so we don't spend ~40 min
// grinding to fill a 16-block damage window before the
// first jump on a damage zone we entered cleanly. Doesn't
// fire on Pass N (threshold=u64::MAX).
//
// b. **Window-based** — original behaviour: 12% bad in a
// sliding window of 16 outer reads. Pass N's only path,
// and Pass 1's fallback if the failures are scattered
// enough that we don't hit the consecutive threshold.
const MAX_JUMP_MULTIPLIER: u64 = 64;
let fast_trigger = !ctx.bisecting && ctx.consecutive_outer_failures >= ctx.fast_jump_threshold;
let window_trigger =
ctx.damage_window.len() >= ctx.damage_window_max && bad_pct >= ctx.damage_threshold_pct;
if fast_trigger || window_trigger {
let mult = ctx.jump_multiplier.min(MAX_JUMP_MULTIPLIER);
let sectors = JUMP_BASE_SECTORS
.saturating_mul(ctx.batch as u64)
.saturating_mul(mult);
ctx.jump_multiplier = (ctx.jump_multiplier.saturating_mul(2)).min(MAX_JUMP_MULTIPLIER);
// Reset the outer-failure counter so a long damaged region
// doesn't keep firing fast-jump every read after the initial
// jump fired. The window-based trigger handles further jumps.
ctx.consecutive_outer_failures = 0;
ctx.jumps_taken += 1;
return ReadAction::JumpAhead {
sectors,
pause_secs: pause_secs + POST_JUMP_EXTRA_PAUSE_SECS,
};
}
// 8. Default: zero-fill the failed batch as NonTrimmed and pause
// before the next read.
ReadAction::SkipBlock { pause_secs }
}
#[cfg(test)]
mod tests {
use super::*;
use crate::error::Error;
use crate::scsi::ScsiSense;
fn medium_err() -> Error {
Error::DiscRead {
sector: 100,
status: Some(2),
sense: Some(ScsiSense {
sense_key: scsi::SENSE_KEY_MEDIUM_ERROR,
asc: 0x11,
ascq: 0x05,
}),
}
}
fn hardware_err() -> Error {
Error::DiscRead {
sector: 100,
status: Some(2),
sense: Some(ScsiSense {
sense_key: scsi::SENSE_KEY_HARDWARE_ERROR,
asc: 0x44,
ascq: 0x00,
}),
}
}
fn illegal_request_err() -> Error {
Error::DiscRead {
sector: 100,
status: Some(2),
sense: Some(ScsiSense {
sense_key: scsi::SENSE_KEY_ILLEGAL_REQUEST,
asc: 0x24,
ascq: 0x00,
}),
}
}
#[test]
fn pass_n_marginal_with_batch_gt_1_bisects() {
let mut ctx = ReadCtx::for_patch(32);
let action = handle_read_error(&medium_err(), &mut ctx);
assert_eq!(action, ReadAction::Bisect);
}
#[test]
fn pass_1_marginal_jumps_immediately_not_bisecting() {
// 2026-05-11 wedge-prevention rewrite: Pass 1 jumps on the
// FIRST marginal error (fast_jump_threshold=1) rather than
// SkipBlock. Retrying the same LBA quickly is what triggers
// the BU40N's firmware fast-fail transition; immediate jump
// prevents the cascade. Pass N still bisects (its job is
// per-sector recovery on already-known-bad LBAs).
let mut ctx = ReadCtx::for_sweep(32);
let action = handle_read_error(&medium_err(), &mut ctx);
match action {
ReadAction::JumpAhead { .. } => {}
other => panic!("expected JumpAhead on first Pass 1 marginal error, got {other:?}"),
}
}
#[test]
fn medium_error_with_batch_1_skips() {
let mut ctx = ReadCtx::for_patch(1);
let action = handle_read_error(&medium_err(), &mut ctx);
match action {
ReadAction::SkipBlock { pause_secs } => assert!(pause_secs >= 1),
other => panic!("expected SkipBlock, got {other:?}"),
}
}
#[test]
fn medium_error_while_bisecting_does_not_recurse() {
let mut ctx = ReadCtx::for_patch(32);
ctx.bisecting = true;
let action = handle_read_error(&medium_err(), &mut ctx);
match action {
ReadAction::SkipBlock { .. } => {}
other => panic!("expected SkipBlock, got {other:?}"),
}
}
#[test]
fn pass_1_jumps_immediately_on_first_outer_failure() {
// 2026-05-11 rewrite: fast_jump_threshold is 1 on Pass 1, not
// 4. Even ONE error triggers a jump because BU40N's firmware
// fast-fail mode is sensitive to retry cadence. The wedge
// observed 2026-05-11 happened at 7 errors / 6.5s — by then
// we were already wedged. Jumping on error #1 means we
// physically can't reach the cascade.
let mut ctx = ReadCtx::for_sweep(32);
let a = handle_read_error(&medium_err(), &mut ctx);
assert!(
matches!(a, ReadAction::JumpAhead { .. }),
"expected JumpAhead on first outer failure (fast_jump_threshold=1), got {a:?}"
);
}
#[test]
fn pass_n_does_not_fast_jump() {
// Pass N's whole reason to exist is to grind on bad ranges.
// It should NOT bail after 4 consecutive failures the way
// Pass 1 does — it bisects and skips with proper recovery.
let mut ctx = ReadCtx::for_patch(32);
for _ in 0..4 {
let a = handle_read_error(&medium_err(), &mut ctx);
assert!(
!matches!(a, ReadAction::JumpAhead { .. }),
"Pass N must not fast-jump; got {a:?}"
);
}
}
#[test]
fn outer_success_resets_consecutive_outer_failures() {
// With fast_jump_threshold=1 each Pass 1 error fires a jump
// and resets `consecutive_outer_failures` to 0 inside the
// handler. So we can't accumulate "3" the old way — instead,
// verify the counter goes back to 0 after on_success too.
let mut ctx = ReadCtx::for_sweep(32);
handle_read_error(&medium_err(), &mut ctx);
// After fast-jump, consecutive_outer_failures already 0.
assert_eq!(ctx.consecutive_outer_failures, 0);
// on_success keeps it at 0 (defensive).
ctx.bisecting = false;
ctx.on_success();
assert_eq!(ctx.consecutive_outer_failures, 0);
}
#[test]
fn bisect_inner_success_does_not_reset_outer_counter() {
let mut ctx = ReadCtx::for_patch(32);
for _ in 0..3 {
handle_read_error(&medium_err(), &mut ctx);
}
assert_eq!(ctx.consecutive_outer_failures, 3);
// A successful inner-sector read during bisect is not the
// same as escaping the bad outer batch.
ctx.bisecting = true;
ctx.on_success();
assert_eq!(
ctx.consecutive_outer_failures, 3,
"bisect inner success must not reset outer-failure counter"
);
}
#[test]
fn pass_1_hardware_error_jumps_ahead_not_aborts() {
// New wedge-skip policy: Pass 1 (bisect_on_marginal=false)
// should JumpAhead with a 1 GB skip + cooldown pause instead
// of immediately aborting. Aborting on first wedge was the
// pre-fix behavior that killed rips at 48% on damaged discs.
let mut ctx = ReadCtx::for_sweep(32);
let action = handle_read_error(&hardware_err(), &mut ctx);
match action {
ReadAction::JumpAhead {
sectors,
pause_secs,
} => {
assert_eq!(sectors, WEDGE_JUMP_SECTORS);
assert_eq!(pause_secs, WEDGE_PAUSE_SECS);
}
other => panic!("expected JumpAhead, got {other:?}"),
}
assert_eq!(ctx.wedge_count, 1);
}
#[test]
fn pass_1_hardware_error_aborts_after_threshold() {
// After WEDGE_ABORT_THRESHOLD consecutive wedges with no good
// read in between, autorip should see a real AbortPass so it
// can surface "drive is stuck, power-cycle required" to the
// user — rather than looping forever on a permanently bricked
// drive.
let mut ctx = ReadCtx::for_sweep(32);
for i in 0..WEDGE_ABORT_THRESHOLD - 1 {
let action = handle_read_error(&hardware_err(), &mut ctx);
assert!(
matches!(action, ReadAction::JumpAhead { .. }),
"iter {i}: expected JumpAhead, got {action:?}"
);
}
// The Nth wedge crosses the threshold.
let action = handle_read_error(&hardware_err(), &mut ctx);
assert_eq!(action, ReadAction::AbortPass);
}
#[test]
fn pass_1_good_read_resets_wedge_count() {
// A single successful read between wedges must clear the
// skip counter — otherwise a disc with a few scattered bad
// zones would eventually run out of skip budget even though
// the drive was recovering between zones.
let mut ctx = ReadCtx::for_sweep(32);
for _ in 0..(WEDGE_ABORT_THRESHOLD - 1) {
handle_read_error(&hardware_err(), &mut ctx);
}
assert_eq!(ctx.wedge_count, WEDGE_ABORT_THRESHOLD - 1);
ctx.on_success();
assert_eq!(ctx.wedge_count, 0);
// After the success, we should still get JumpAhead (not
// AbortPass) on the next wedge.
let action = handle_read_error(&hardware_err(), &mut ctx);
assert!(matches!(action, ReadAction::JumpAhead { .. }));
}
#[test]
fn pass_n_hardware_error_also_skips_not_aborts() {
// 2026-05-11 reframe: error handling is centralized, the
// wedge is a code-induced state, and the avoidance principle
// (skip + pause + continue) applies to Pass N too. Previously
// Pass N AbortPass'd on first wedge — same fatal-at-48% bug
// Pass 1 had pre-fix. Now Pass N gets a smaller skip
// (WEDGE_PASS_N_SKIP_SECTORS, not the 1 GB Pass 1 jump)
// because Pass N's job IS to revisit specific NonTrimmed
// ranges; over-skipping abandons recoverable sectors.
let mut ctx = ReadCtx::for_patch(1);
let action = handle_read_error(&hardware_err(), &mut ctx);
match action {
ReadAction::JumpAhead {
sectors,
pause_secs,
} => {
assert_eq!(sectors, WEDGE_PASS_N_SKIP_SECTORS);
assert_eq!(pause_secs, WEDGE_PAUSE_SECS);
}
other => panic!("expected JumpAhead, got {other:?}"),
}
assert_eq!(ctx.wedge_count, 1);
}
#[test]
fn pass_n_hardware_error_aborts_after_threshold() {
// Same threshold as Pass 1 — after WEDGE_ABORT_THRESHOLD
// consecutive wedges with no good read in between, give up.
let mut ctx = ReadCtx::for_patch(1);
for _ in 0..WEDGE_ABORT_THRESHOLD - 1 {
let action = handle_read_error(&hardware_err(), &mut ctx);
assert!(matches!(action, ReadAction::JumpAhead { .. }));
}
let action = handle_read_error(&hardware_err(), &mut ctx);
assert_eq!(action, ReadAction::AbortPass);
}
#[test]
fn pass_1_illegal_request_also_routes_to_wedge_skip() {
// ILLEGAL_REQUEST is the other half of the wedge family:
// drive saying "I won't parse your CDB" after entering the
// fast-fail state. Same treatment as HARDWARE_ERROR.
let mut ctx = ReadCtx::for_sweep(32);
let action = handle_read_error(&illegal_request_err(), &mut ctx);
assert!(matches!(action, ReadAction::JumpAhead { .. }));
}
#[test]
fn long_failure_streak_extends_pause_on_pass_n() {
// Pass N keeps the cooldown behaviour: after many consecutive
// failures, pauses extend to give the drive time to recover.
// Pass 1 explicitly does NOT pause — see
// `pass_1_does_not_pause_on_skip` below.
let mut ctx = ReadCtx::for_patch(1);
for _ in 0..15 {
handle_read_error(&medium_err(), &mut ctx);
}
let final_action = handle_read_error(&medium_err(), &mut ctx);
match final_action {
ReadAction::SkipBlock { pause_secs } => {
assert!(pause_secs >= CONSECUTIVE_FAIL_LONG_PAUSE_SECS);
}
ReadAction::JumpAhead { pause_secs, .. } => {
assert!(pause_secs >= CONSECUTIVE_FAIL_LONG_PAUSE_SECS);
}
other => panic!("expected long-pause action, got {other:?}"),
}
}
#[test]
fn pass_1_zone_entry_uses_long_cooldown() {
// 2026-05-11 wedge-prevention rewrite: Pass 1's FIRST error
// (zone entry) gets a 30 s ZONE_ENTRY_COOLDOWN_SECS pause +
// a 2 s POST_JUMP_EXTRA on top (since we're also jumping).
// The long pause prevents the retry cadence that triggers
// firmware fast-fail. Subsequent errors in the same zone fall
// back to the standard 5 s FAIL_PAUSE_SECS.
let mut ctx = ReadCtx::for_sweep(32);
let action = handle_read_error(&medium_err(), &mut ctx);
match action {
ReadAction::JumpAhead { pause_secs, .. } => {
assert_eq!(
pause_secs,
ZONE_ENTRY_COOLDOWN_SECS + POST_JUMP_EXTRA_PAUSE_SECS,
"first-error pause should be 30 + 2 = 32 s"
);
}
other => panic!("expected JumpAhead on first Pass 1 error, got {other:?}"),
}
}
#[test]
fn pass_n_pauses_uniformly_on_failed_read() {
// Pass N (bisect_on_marginal=true) is exempt from the
// zone-entry long pause — its whole job is to retry single
// sectors on already-known-bad LBAs, and the 30 s pause every
// single-sector failure would multiply slow recovery
// pointlessly. Pass N keeps the standard 5 s FAIL_PAUSE_SECS.
let mut ctx = ReadCtx::for_patch(1);
let action = handle_read_error(&medium_err(), &mut ctx);
match action {
ReadAction::SkipBlock { pause_secs } => assert_eq!(pause_secs, FAIL_PAUSE_SECS),
ReadAction::JumpAhead { pause_secs, .. } => {
assert_eq!(pause_secs, FAIL_PAUSE_SECS + POST_JUMP_EXTRA_PAUSE_SECS)
}
ReadAction::Bisect => {}
other => panic!("expected pausing action, got {other:?}"),
}
}
#[test]
fn damage_window_fills_then_jumps() {
let mut ctx = ReadCtx::for_sweep(1);
ctx.damage_window_max = 4;
ctx.damage_threshold_pct = 50;
let mut saw_jump = false;
for _ in 0..6 {
let a = handle_read_error(&medium_err(), &mut ctx);
if matches!(a, ReadAction::JumpAhead { .. }) {
saw_jump = true;
break;
}
}
assert!(
saw_jump,
"expected at least one JumpAhead in 6 failures with 50% threshold"
);
}
#[test]
fn on_success_resets_failure_counters_and_pushes_window() {
let mut ctx = ReadCtx::for_sweep(32);
for _ in 0..3 {
handle_read_error(&medium_err(), &mut ctx);
}
assert!(ctx.consecutive_failures > 0);
ctx.bisecting = false;
ctx.on_success();
assert_eq!(ctx.consecutive_good, 1);
assert_eq!(ctx.consecutive_failures, 0);
assert!(*ctx.damage_window.last().unwrap());
}
}