fix(producer): correct short VFR frame coverage

packages/engine/src/index.ts

@@ -185,6 +185,7 @@ export {
   resolveFinalFrameExtractionWindow,
   resolveVideoExtractionDuration,
   resolvePlayableVideoDuration,
+  extractionFrameCountForDuration,
   resolveProjectRelativeSrc,
   getFrameAtTime,
   createFrameLookupTable,

packages/engine/src/services/videoFrameExtractor.test.ts

@@ -19,6 +19,7 @@ import {
   parseImageElements,
   extractAllVideoFrames,
   extractVideoFramesRange,
+  extractionFrameCountForDuration,
   createFrameLookupTable,
   resolveProjectRelativeSrc,
   resolveFrameFormat,
@@ -307,6 +308,45 @@ describe("resolveVideoExtractionDuration", () => {
   });
 });
 
+describe("extractionFrameCountForDuration", () => {
+  it("uses the same VFR ceil and CFR nearest-boundary rules as FFmpeg", () => {
+    expect(extractionFrameCountForDuration(0.466666, 30, true)).toBe(14);
+    expect(extractionFrameCountForDuration(0.466666, 30, false)).toBe(14);
+    expect(extractionFrameCountForDuration(0.616666, 30, true)).toBe(19);
+    expect(extractionFrameCountForDuration(0.616666, 30, false)).toBe(18);
+  });
+
+  it.each([
+    [0.33 - 0.03, 30, 9],
+    [0.29 - 0.04, 24, 6],
+    [0.35 - 0.05, 60, 18],
+    [4.03 - 3.53, 30, 15],
+    [4.03 - 3.78, 24, 6],
+  ])(
+    "snaps floating-point integral boundaries before VFR ceil (%s seconds at %i fps)",
+    (duration, fps, expectedFrames) => {
+      expect(extractionFrameCountForDuration(duration, fps, true)).toBe(expectedFrames);
+    },
+  );
+
+  it("still ceils a genuine fractional boundary beyond floating-point noise", () => {
+    expect(extractionFrameCountForDuration(0.300001, 30, true)).toBe(10);
+  });
+
+  it("matches FFmpeg's six-digit duration parsing", () => {
+    expect(extractionFrameCountForDuration(0.6000009, 30, true)).toBe(18);
+    expect(extractionFrameCountForDuration(0.600001, 30, true)).toBe(19);
+    expect(extractionFrameCountForDuration(2.05, 30, false)).toBe(62);
+  });
+
+  it("fails closed for invalid durations and emits one frame for positive sub-frame work", () => {
+    expect(extractionFrameCountForDuration(Number.NaN, 30, true)).toBe(0);
+    expect(extractionFrameCountForDuration(1, 0, true)).toBe(0);
+    expect(extractionFrameCountForDuration(0, 30, true)).toBe(0);
+    expect(extractionFrameCountForDuration(0.001, 30, false)).toBe(1);
+  });
+});
+
 describe("video extraction failure taxonomy and bounded retry", () => {
   it("classifies missing and transient HTTP sources without exposing retry ambiguity", () => {
     expect(classifyVideoExtractionError(new Error("HTTP 404: Not Found"))).toMatchObject({
@@ -2067,6 +2107,57 @@ describe.skipIf(!HAS_FFMPEG)("extractAllVideoFrames on a VFR source", () => {
     expect(supersetDirNames(outputDir)).toEqual([]);
   }, 60_000);
 
+  it.each([
+    { label: "decimal underflow half-frame", duration: 2.05, offset: 1, expectedFrames: 62 },
+    {
+      label: "non-half-integer boundary",
+      duration: 0.616666,
+      offset: 0.1,
+      expectedFrames: 18,
+    },
+  ])(
+    "keeps direct and superset CFR extraction equal at a $label",
+    async ({ label, duration, offset, expectedFrames }) => {
+      const fixtureKey = label.replaceAll(" ", "-");
+      const src = await synthCfrClip(`superset-cfr-${fixtureKey}.mp4`, 4);
+      const groupedOutputDir = join(FIXTURE_DIR, `out-superset-cfr-${fixtureKey}`);
+      const directOutputDir = join(FIXTURE_DIR, `out-direct-cfr-${fixtureKey}`);
+      mkdirSync(groupedOutputDir, { recursive: true });
+      mkdirSync(directOutputDir, { recursive: true });
+
+      const grouped = await extractAllVideoFrames(
+        [
+          cfrClipElement(`${fixtureKey}-base`, src, duration, 0),
+          cfrClipElement(`${fixtureKey}-member`, src, duration, offset),
+        ],
+        FIXTURE_DIR,
+        { fps: 30, outputDir: groupedOutputDir },
+      );
+      const direct = await extractVideoFramesRange(src, `${fixtureKey}-direct`, offset, duration, {
+        fps: 30,
+        outputDir: directOutputDir,
+        format: "jpg",
+      });
+
+      expect(grouped.errors).toEqual([]);
+      expect(direct.totalFrames).toBe(expectedFrames);
+      expect(extractedFor(grouped, `${fixtureKey}-base`).totalFrames).toBe(expectedFrames);
+      expect(extractedFor(grouped, `${fixtureKey}-member`).totalFrames).toBe(expectedFrames);
+      expect(statSync(framePath(grouped, `${fixtureKey}-base`, Math.round(offset * 30))).ino).toBe(
+        statSync(framePath(grouped, `${fixtureKey}-member`, 0)).ino,
+      );
+      for (let frame = 0; frame < expectedFrames; frame += 1) {
+        expect(
+          readFileSync(framePath(grouped, `${fixtureKey}-member`, frame)).equals(
+            readFileSync(direct.framePaths.get(frame)!),
+          ),
+        ).toBe(true);
+      }
+      expect(supersetDirNames(groupedOutputDir)).toEqual([]);
+    },
+    60_000,
+  );
+
   it("does not superset disjoint trims", async () => {
     const SRC = await synthCfrClip("superset-disjoint-src.mp4", 10);
     const outputDir = join(FIXTURE_DIR, "out-superset-disjoint");
@@ -2103,6 +2194,77 @@ describe.skipIf(!HAS_FFMPEG)("extractAllVideoFrames on a VFR source", () => {
     expect(supersetDirNames(outputDir)).toEqual([]);
   }, 60_000);
 
+  it("keeps overlapping VFR trims direct because CFR resampling phase resets per seek", async () => {
+    const outputDir = join(FIXTURE_DIR, "out-vfr-superset-short");
+    mkdirSync(outputDir, { recursive: true });
+
+    const result = await extractAllVideoFrames(
+      [
+        cfrClipElement("vfr-short-a", VFR_FIXTURE, 0.616666, 0),
+        cfrClipElement("vfr-short-b", VFR_FIXTURE, 0.616666, 0.1),
+      ],
+      FIXTURE_DIR,
+      { fps: 30, outputDir },
+    );
+
+    expect(result.errors).toEqual([]);
+    expect(extractedFor(result, "vfr-short-a").metadata.isVFR).toBe(true);
+    expect(extractedFor(result, "vfr-short-a").totalFrames).toBe(19);
+    expect(extractedFor(result, "vfr-short-b").totalFrames).toBe(19);
+    expect(statSync(framePath(result, "vfr-short-a", 3)).ino).not.toBe(
+      statSync(framePath(result, "vfr-short-b", 0)).ino,
+    );
+    expect(supersetDirNames(outputDir)).toEqual([]);
+  }, 60_000);
+
+  it("keeps batched and direct VFR extraction equal at a floating integral boundary", async () => {
+    const groupedOutputDir = join(FIXTURE_DIR, "out-vfr-superset-integral-boundary");
+    const directOutputDir = join(FIXTURE_DIR, "out-vfr-direct-integral-boundary");
+    mkdirSync(groupedOutputDir, { recursive: true });
+    mkdirSync(directOutputDir, { recursive: true });
+
+    const first: VideoElement = {
+      id: "vfr-integral-a",
+      src: VFR_FIXTURE,
+      start: 0.03,
+      end: 0.33,
+      mediaStart: 0.03,
+      loop: false,
+      hasAudio: false,
+    };
+    const second: VideoElement = {
+      ...first,
+      id: "vfr-integral-b",
+      mediaStart: 0.13,
+    };
+
+    const direct = await extractAllVideoFrames([{ ...second }], FIXTURE_DIR, {
+      fps: 30,
+      outputDir: directOutputDir,
+    });
+    const grouped = await extractAllVideoFrames([{ ...first }, second], FIXTURE_DIR, {
+      fps: 30,
+      outputDir: groupedOutputDir,
+    });
+
+    expect(direct.errors).toEqual([]);
+    expect(grouped.errors).toEqual([]);
+    expect(extractedFor(direct, second.id).totalFrames).toBe(9);
+    expect(extractedFor(grouped, first.id).totalFrames).toBe(9);
+    expect(extractedFor(grouped, second.id).totalFrames).toBe(9);
+    for (let frame = 0; frame < 9; frame += 1) {
+      expect(
+        readFileSync(framePath(grouped, second.id, frame)).equals(
+          readFileSync(framePath(direct, second.id, frame)),
+        ),
+      ).toBe(true);
+    }
+    expect(statSync(framePath(grouped, first.id, 3)).ino).not.toBe(
+      statSync(framePath(grouped, second.id, 0)).ino,
+    );
+    expect(supersetDirNames(groupedOutputDir)).toEqual([]);
+  }, 60_000);
+
   it("publishes overlapping superset slices to cache entries and hits them on the next render", async () => {
     const CACHE_DIR = mkdtempSync(join(tmpdir(), "hf-extract-superset-cache-test-"));
     const SRC = await synthCfrClip("superset-cache-src.mp4", 10);

packages/engine/src/services/videoFrameExtractor.ts

@@ -81,6 +81,62 @@ export function isVideoFrameFormat(value: unknown): value is VideoFrameFormat {
   return typeof value === "string" && (VIDEO_FRAME_FORMATS as readonly string[]).includes(value);
 }
 
+/**
+ * Resolve the frame count produced for a requested extraction duration.
+ *
+ * CFR extraction uses FFmpeg's fps filter, whose end boundary rounds to the
+ * nearest frame. The VFR path normalizes with `-fps_mode cfr -r`, whose end
+ * boundary rounds up. Keep this calculation shared by superset slicing and
+ * producer coverage accounting so a complete VFR extraction cannot be
+ * rejected because the two paths disagree by one frame.
+ */
+export function extractionFrameCountForDuration(
+  durationSeconds: number,
+  fps: number,
+  isVFR: boolean,
+): number {
+  if (!Number.isFinite(durationSeconds) || !Number.isFinite(fps)) return 0;
+  if (durationSeconds <= 0 || fps <= 0) return 0;
+  // FFmpeg receives `String(durationSeconds)` and parses at microsecond
+  // precision. Derive the integer microseconds from that same decimal text:
+  // multiplying the binary float first is not equivalent (`2.05 * 1e6` is
+  // 2049999.9999999998 in JS and would incorrectly truncate one microsecond).
+  const serialized = String(durationSeconds).toLowerCase();
+  const decimal = /^(\d+)(?:\.(\d+))?(?:e([+-]?\d+))?$/.exec(serialized);
+  if (!decimal) return 0;
+  const whole = decimal[1] ?? "0";
+  const fraction = decimal[2] ?? "";
+  const exponent = Number.parseInt(decimal[3] ?? "0", 10);
+  const digits = BigInt(`${whole}${fraction}`);
+  const microsecondScale = exponent + 6 - fraction.length;
+  const microseconds =
+    microsecondScale >= 0
+      ? digits * 10n ** BigInt(microsecondScale)
+      : digits / 10n ** BigInt(-microsecondScale);
+
+  // Keep the frame-boundary calculation rational too. Converting the exact
+  // microseconds back to a binary float recreates the same problem at .5-frame
+  // boundaries (`2.05 * 30` is 61.49999999999999 in JS).
+  const serializedFps = String(fps).toLowerCase();
+  const fpsDecimal = /^(\d+)(?:\.(\d+))?(?:e([+-]?\d+))?$/.exec(serializedFps);
+  if (!fpsDecimal) return 0;
+  const fpsWhole = fpsDecimal[1] ?? "0";
+  const fpsFraction = fpsDecimal[2] ?? "";
+  const fpsExponent = Number.parseInt(fpsDecimal[3] ?? "0", 10);
+  const fpsDigits = BigInt(`${fpsWhole}${fpsFraction}`);
+  const fpsScale = fpsExponent - fpsFraction.length;
+  const fpsNumerator = fpsScale >= 0 ? fpsDigits * 10n ** BigInt(fpsScale) : fpsDigits;
+  const fpsDenominator = fpsScale >= 0 ? 1n : 10n ** BigInt(-fpsScale);
+
+  const frameNumerator = microseconds * fpsNumerator;
+  const frameDenominator = 1_000_000n * fpsDenominator;
+  const frameCount = isVFR
+    ? (frameNumerator + frameDenominator - 1n) / frameDenominator
+    : (2n * frameNumerator + frameDenominator) / (2n * frameDenominator);
+  const frames = Number(frameCount);
+  return Math.max(1, Number.isSafeInteger(frames) ? frames : Number.MAX_SAFE_INTEGER);
+}
+
 export interface ExtractionOptions {
   fps: number;
   outputDir: string;
@@ -1102,6 +1158,12 @@ function buildSupersetGroup(
 ): SupersetGroupPlan | null {
   if (misses.length < 2) return null;
   if (misses.some(({ work }) => work.finalFrameOnly)) return null;
+  // VFR normalization (`-fps_mode cfr -r`) establishes its duplicate/drop
+  // phase relative to each seek. A union extraction therefore cannot be
+  // sliced into the same frames as independently sought member ranges, even
+  // when their offsets land on an integral output-frame boundary. Keep VFR
+  // ranges direct until the extractor has a proven absolute timestamp phase.
+  if (misses.some(({ work }) => work.metadata.isVFR)) return null;
   const baseStart = Math.min(...misses.map(({ work }) => work.video.mediaStart));
   if (!misses.every(({ work }) => isIntegralFrameOffset(work.video.mediaStart - baseStart, fps))) {
     return null;
@@ -1190,7 +1252,11 @@ function sliceSupersetMember(
   // offset_i + k, so its source time is
   // baseStart + (offset_i + k) / fps = mediaStart_i + k / fps.
   // The frame-alignment precondition is what makes offset_i integral.
-  const requestedFrames = Math.round(work.videoDuration * fps);
+  const requestedFrames = extractionFrameCountForDuration(
+    work.videoDuration,
+    fps,
+    work.metadata.isVFR,
+  );
   const availableFrames = Math.max(0, superset.totalFrames - member.offsetFrames);
   const frameCount = Math.min(requestedFrames, availableFrames);
   for (let i = 0; i < frameCount; i += 1) {

packages/producer/src/services/render/videoFrameCoverage.test.ts

@@ -160,7 +160,7 @@ describe("computeVideoFrameCoverage", () => {
     expect(() => assertVideoFrameCoverage(reports, 0.95)).not.toThrow();
   });
 
-  it("keeps ceil coverage for the VFR extraction branch", () => {
+  it("tolerates a single FFmpeg boundary frame on a short 18/19 VFR extraction", () => {
     const videos = [makeVideo({ id: "short-vfr", start: 0, end: 0.616666 })];
     const reports = computeVideoFrameCoverage(
       videos,
@@ -172,7 +172,7 @@ describe("computeVideoFrameCoverage", () => {
       capturedFrames: 18,
       ratio: 18 / 19,
     });
-    expect(() => assertVideoFrameCoverage(reports, 0.95)).toThrow(VideoFrameCoverageError);
+    expect(() => assertVideoFrameCoverage(reports, 0.95)).not.toThrow();
   });
 
   it("still fails closed when a positive sub-frame clip captured zero frames", () => {
@@ -344,6 +344,86 @@ describe("assertVideoFrameCoverage", () => {
     expect(() => assertVideoFrameCoverage(reports, 0.95)).toThrow(VideoFrameCoverageError);
   });
 
+  it.each([
+    [13, 14],
+    [18, 19],
+  ])(
+    "tolerates exactly one nonzero boundary frame for a short clip (%i/%i)",
+    (capturedFrames, expectedFrames) => {
+      const reports = [
+        {
+          videoId: "short-boundary",
+          clipStart: 0,
+          clipEnd: expectedFrames / 30,
+          expectedFrames,
+          capturedFrames,
+          ratio: capturedFrames / expectedFrames,
+        },
+      ];
+      expect(() => assertVideoFrameCoverage(reports, 0.95)).not.toThrow();
+    },
+  );
+
+  it("does not treat a one-frame deficit as tolerance when it represents major loss", () => {
+    const reports = [
+      {
+        videoId: "major-loss",
+        clipStart: 0,
+        clipEnd: 2 / 30,
+        expectedFrames: 2,
+        capturedFrames: 1,
+        ratio: 0.5,
+      },
+    ];
+    expect(() => assertVideoFrameCoverage(reports, 0.95)).toThrow(VideoFrameCoverageError);
+  });
+
+  it("does not tolerate two missing frames, zero captured frames, or an exact threshold", () => {
+    const report = {
+      videoId: "short-incomplete",
+      clipStart: 0,
+      clipEnd: 19 / 30,
+      expectedFrames: 19,
+      capturedFrames: 17,
+      ratio: 17 / 19,
+    };
+    expect(() => assertVideoFrameCoverage([report], 0.95)).toThrow(VideoFrameCoverageError);
+    expect(() =>
+      assertVideoFrameCoverage([{ ...report, capturedFrames: 0, ratio: 0 }], 0.95),
+    ).toThrow(VideoFrameCoverageError);
+    expect(() =>
+      assertVideoFrameCoverage([{ ...report, capturedFrames: 18, ratio: 18 / 19 }], 1),
+    ).toThrow(VideoFrameCoverageError);
+  });
+
+  it("does not apply the one-frame tolerance to longer clips", () => {
+    const reports = [
+      {
+        videoId: "long-boundary",
+        clipStart: 0,
+        clipEnd: 21 / 30,
+        expectedFrames: 21,
+        capturedFrames: 20,
+        ratio: 20 / 21,
+      },
+    ];
+    expect(() => assertVideoFrameCoverage(reports, 0.99)).toThrow(VideoFrameCoverageError);
+  });
+
+  it("still rejects a material long-clip shortfall even when it is five frames", () => {
+    const reports = [
+      {
+        videoId: "long-partial",
+        clipStart: 0,
+        clipEnd: 89 / 30,
+        expectedFrames: 89,
+        capturedFrames: 84,
+        ratio: 84 / 89,
+      },
+    ];
+    expect(() => assertVideoFrameCoverage(reports, 0.95)).toThrow(VideoFrameCoverageError);
+  });
+
   it("respects a threshold override — 0.5 passes 60% coverage", () => {
     const reports = [
       {