fix(drone): harden RFDetector threading, subprocess lifecycle, and frequency accuracy

- Replace _running bool with threading.Event for correct cross-thread visibility
- Add _proc_lock to guard _rtl_proc/_hackrf_proc across worker/main threads
- Use register_process + safe_terminate (pipe close + SIGKILL fallback on timeout)
- Compute HackRF frequency as band midpoint (hz_low+hz_high)//2, not hz_low
- Guard start() for idempotency — double-call no longer leaks threads

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

tests/test_drone_rf_detector.py

@@ -56,7 +56,7 @@ def test_hackrf_sweep_line_emits_observation(detector):
     obs = q.get_nowait()
     assert isinstance(obs, RFObservation)
     assert obs.hardware == "HACKRF"
-    assert obs.frequency_hz == hz_low
+    assert obs.frequency_hz == (hz_low + hz_high) // 2
     assert obs.rssi < 0
 
 

utils/drone/rf_detector.py

@@ -11,6 +11,8 @@ import subprocess
 import threading
 from datetime import datetime, timezone
 
+from utils.process import register_process, safe_terminate
+
 from .models import RFObservation
 from .signatures import match_signature
 
@@ -32,14 +34,16 @@ def _in_drone_band(freq_hz: int) -> bool:
 class RFDetector:
     def __init__(self, output_queue: queue.Queue) -> None:
         self._queue = output_queue
-        self._running = False
+        self._stop_event = threading.Event()
+        self._stop_event.set()  # starts in stopped state
+        self._proc_lock = threading.Lock()
         self._rtl_proc: subprocess.Popen | None = None
         self._hackrf_proc: subprocess.Popen | None = None
         self._threads: list[threading.Thread] = []
 
     @property
     def running(self) -> bool:
-        return self._running
+        return not self._stop_event.is_set()
 
     def _handle_rtl433_line(self, line: str) -> None:
         try:
@@ -71,6 +75,7 @@ class RFDetector:
             return
         try:
             hz_low = int(parts[2])
+            hz_high = int(parts[3])
             db_values = [float(p) for p in parts[6:] if p]
         except (ValueError, IndexError):
             return
@@ -79,13 +84,14 @@ class RFDetector:
         avg_db = sum(db_values) / len(db_values)
         if avg_db < _HACKRF_THRESHOLD_DBM:
             return
-        if not _in_drone_band(hz_low):
+        freq_hz = (hz_low + hz_high) // 2
+        if not _in_drone_band(freq_hz):
             return
-        protocol = match_signature(hz_low)
+        protocol = match_signature(freq_hz)
         with contextlib.suppress(queue.Full):
             self._queue.put_nowait(
                 RFObservation(
-                    frequency_hz=hz_low,
+                    frequency_hz=freq_hz,
                     protocol=protocol,
                     rssi=avg_db,
                     hardware="HACKRF",
@@ -101,11 +107,14 @@ class RFDetector:
         cmd = [rtl_bin, "-d", str(device_index), "-F", "json", "-f", "433920000", "-f", "868300000"]
         try:
             proc = subprocess.Popen(cmd, stdout=subprocess.PIPE, stderr=subprocess.DEVNULL)
-            self._rtl_proc = proc
+            register_process(proc)
+            with self._proc_lock:
+                self._rtl_proc = proc
             for raw_line in iter(proc.stdout.readline, b""):
-                if not self._running:
+                if self._stop_event.is_set():
                     break
                 self._handle_rtl433_line(raw_line.decode("utf-8", errors="replace").strip())
+            safe_terminate(proc)
         except Exception as exc:
             logger.warning("rtl_433 error: %s", exc)
 
@@ -117,16 +126,21 @@ class RFDetector:
         cmd = [hackrf_bin, "-f", "2400:2484", "-f", "5725:5875", "-w", "1000000"]
         try:
             proc = subprocess.Popen(cmd, stdout=subprocess.PIPE, stderr=subprocess.DEVNULL)
-            self._hackrf_proc = proc
+            register_process(proc)
+            with self._proc_lock:
+                self._hackrf_proc = proc
             for raw_line in iter(proc.stdout.readline, b""):
-                if not self._running:
+                if self._stop_event.is_set():
                     break
                 self._handle_hackrf_line(raw_line.decode("utf-8", errors="replace").strip())
+            safe_terminate(proc)
         except Exception as exc:
             logger.warning("hackrf_sweep error: %s", exc)
 
     def start(self, rtl_sdr_index: int = 0, use_hackrf: bool = True) -> None:
-        self._running = True
+        if self.running:
+            return
+        self._stop_event.clear()
         t1 = threading.Thread(target=self._run_rtl433, args=(rtl_sdr_index,), daemon=True)
         t1.start()
         self._threads.append(t1)
@@ -136,11 +150,12 @@ class RFDetector:
             self._threads.append(t2)
 
     def stop(self) -> None:
-        self._running = False
-        for proc in (self._rtl_proc, self._hackrf_proc):
-            if proc:
-                with contextlib.suppress(Exception):
-                    proc.terminate()
-        self._rtl_proc = None
-        self._hackrf_proc = None
+        self._stop_event.set()
+        with self._proc_lock:
+            rtl_proc = self._rtl_proc
+            hackrf_proc = self._hackrf_proc
+            self._rtl_proc = None
+            self._hackrf_proc = None
+        safe_terminate(rtl_proc)
+        safe_terminate(hackrf_proc)
         self._threads.clear()