.env.example

@@ -12,6 +12,9 @@ DATABASE_URL=postgresql+asyncpg://holdslayer:<db-password>@localhost:5432/holdsl
 API_TOKEN=
 
 # --- SIP Trunk ---
+# The mock engine must be requested explicitly; an unconfigured trunk
+# without USE_MOCK_SIP=true refuses to start.
+USE_MOCK_SIP=false
 SIP_TRUNK_HOST=sip.yourprovider.com
 SIP_TRUNK_PORT=5060
 SIP_TRUNK_USERNAME=your_sip_username

api/websocket.py

@@ -94,7 +94,7 @@ async def event_stream(websocket: WebSocket):
     # Immediately push current trunk status so the dashboard doesn't start blank
     await _send_trunk_status(websocket, gateway)
 
-    subscription = gateway.event_bus.subscribe()
+    subscription = gateway.event_bus.subscribe(replay_last=25)
 
     try:
         async for event in subscription:

config.py

@@ -11,7 +11,7 @@ from pydantic_settings import BaseSettings, SettingsConfigDict
 class SIPTrunkSettings(BaseSettings):
     """SIP trunk provider configuration."""
 
-    model_config = SettingsConfigDict(env_prefix="SIP_TRUNK_")
+    model_config = SettingsConfigDict(env_prefix="SIP_TRUNK_", env_file=".env", extra="ignore")
 
     host: str = "sip.provider.com"
     port: int = 5060
@@ -24,7 +24,7 @@ class SIPTrunkSettings(BaseSettings):
 class GatewaySIPSettings(BaseSettings):
     """Gateway SIP listener for device registration."""
 
-    model_config = SettingsConfigDict(env_prefix="GATEWAY_SIP_")
+    model_config = SettingsConfigDict(env_prefix="GATEWAY_SIP_", env_file=".env", extra="ignore")
 
     host: str = "0.0.0.0"
     port: int = 5060
@@ -34,7 +34,7 @@ class GatewaySIPSettings(BaseSettings):
 class SpeachesSettings(BaseSettings):
     """Speaches STT service configuration."""
 
-    model_config = SettingsConfigDict(env_prefix="SPEACHES_")
+    model_config = SettingsConfigDict(env_prefix="SPEACHES_", env_file=".env", extra="ignore")
 
     url: str = "http://localhost:22070"
     model: str = "whisper-large-v3"
@@ -43,7 +43,7 @@ class SpeachesSettings(BaseSettings):
 class ClassifierSettings(BaseSettings):
     """Audio classifier thresholds."""
 
-    model_config = SettingsConfigDict(env_prefix="CLASSIFIER_")
+    model_config = SettingsConfigDict(env_prefix="CLASSIFIER_", env_file=".env", extra="ignore")
 
     music_threshold: float = 0.7
     speech_threshold: float = 0.6
@@ -54,7 +54,7 @@ class ClassifierSettings(BaseSettings):
 class LLMSettings(BaseSettings):
     """LLM service configuration (OpenAI-compatible API)."""
 
-    model_config = SettingsConfigDict(env_prefix="LLM_")
+    model_config = SettingsConfigDict(env_prefix="LLM_", env_file=".env", extra="ignore")
 
     base_url: str = "http://localhost:11434/v1"
     model: str = "llama3"
@@ -67,7 +67,7 @@ class LLMSettings(BaseSettings):
 class HoldSlayerSettings(BaseSettings):
     """Hold Slayer behavior settings."""
 
-    model_config = SettingsConfigDict(env_prefix="HOLD_SLAYER_", env_prefix_allow_empty=True)
+    model_config = SettingsConfigDict(env_prefix="HOLD_SLAYER_", env_prefix_allow_empty=True, env_file=".env", extra="ignore")
 
     default_transfer_device: str = Field(
         default="sip_phone", validation_alias="DEFAULT_TRANSFER_DEVICE"
@@ -79,7 +79,7 @@ class HoldSlayerSettings(BaseSettings):
 class TTSSettings(BaseSettings):
     """Rhema TTS service configuration (OpenAI-compatible /v1/audio/speech)."""
 
-    model_config = SettingsConfigDict(env_prefix="TTS_")
+    model_config = SettingsConfigDict(env_prefix="TTS_", env_file=".env", extra="ignore")
 
     base_url: str = "http://localhost:8000"
     model: str = "speaches-ai/Kokoro-82M-v1.0-ONNX"
@@ -92,7 +92,7 @@ class TTSSettings(BaseSettings):
 class ReceptionistSettings(BaseSettings):
     """AI Receptionist behavior settings."""
 
-    model_config = SettingsConfigDict(env_prefix="RECEPTIONIST_")
+    model_config = SettingsConfigDict(env_prefix="RECEPTIONIST_", env_file=".env", extra="ignore")
 
     enabled: bool = True
     greeting_template: str = (
@@ -133,6 +133,11 @@ class Settings(BaseSettings):
     # Outbound-call safety cap (REST + MCP make_call)
     max_concurrent_calls: int = 4
 
+    # Explicit engine mode — the mock engine must be asked for. An
+    # unconfigured trunk without this flag fails startup instead of
+    # silently degrading to a gateway that can't place real calls.
+    use_mock_sip: bool = False
+
     # Notifications
     notify_sms_number: str = ""
 

core/event_bus.py

@@ -20,63 +20,70 @@ class EventBus:
 
     Features:
     - Non-blocking publish (put_nowait)
-    - Automatic dead-subscriber cleanup (full queues are removed)
-    - Event history (last N events for late joiners)
+    - Slow subscribers lose their oldest event, never their subscription
+    - Event history (last N events, replayable to late joiners)
     - Typed event filtering on subscriptions
     - Async iteration via EventSubscription
     """
 
     def __init__(self, max_history: int = 1000):
-        self._subscribers: list[tuple[asyncio.Queue[GatewayEvent], Optional[set[EventType]]]] = []
+        self._subscribers: list[EventSubscription] = []
         self._history: list[GatewayEvent] = []
         self._max_history = max_history
 
     async def publish(self, event: GatewayEvent) -> None:
-        """Publish an event to all subscribers."""
+        """Publish an event to all subscribers.
+
+        A full subscriber queue drops its oldest event (counted on the
+        subscription) — a slow dashboard must never be silently
+        unsubscribed while its socket stays open.
+        """
         self._history.append(event)
         if len(self._history) > self._max_history:
             self._history = self._history[-self._max_history :]
 
         logger.info(f"📡 Event: {event.type.value} | {event.message or ''}")
 
-        dead_queues = []
-        for queue, type_filter in self._subscribers:
-            # Skip if subscriber has a type filter and this event doesn't match
-            if type_filter and event.type not in type_filter:
+        for sub in self._subscribers:
+            if sub.type_filter and event.type not in sub.type_filter:
                 continue
-            try:
-                queue.put_nowait(event)
-            except asyncio.QueueFull:
-                dead_queues.append((queue, type_filter))
-
-        for entry in dead_queues:
-            self._subscribers.remove(entry)
+            sub.deliver(event)
 
     def subscribe(
         self,
         max_size: int = 100,
         event_types: Optional[set[EventType]] = None,
+        replay_last: int = 0,
     ) -> "EventSubscription":
         """
         Create a new subscription.
 
         Args:
-            max_size: Queue depth before subscriber is considered dead.
+            max_size: Queue depth; overflow drops the oldest event.
             event_types: Optional filter — only receive these event types.
                          None means receive everything.
+            replay_last: Seed the queue with up to N most recent
+                         history events (post-filter) before live ones.
 
         Returns:
             An async iterator of GatewayEvents.
         """
         queue: asyncio.Queue[GatewayEvent] = asyncio.Queue(maxsize=max_size)
-        entry = (queue, event_types)
-        self._subscribers.append(entry)
-        return EventSubscription(queue, self, entry)
+        sub = EventSubscription(queue, self, event_types)
+        if replay_last > 0:
+            replayable = [
+                e for e in self._history
+                if not event_types or e.type in event_types
+            ]
+            for event in replayable[-replay_last:]:
+                sub.deliver(event)
+        self._subscribers.append(sub)
+        return sub
 
-    def unsubscribe(self, entry: tuple) -> None:
+    def unsubscribe(self, sub: "EventSubscription") -> None:
         """Remove a subscriber."""
-        if entry in self._subscribers:
-            self._subscribers.remove(entry)
+        if sub in self._subscribers:
+            self._subscribers.remove(sub)
 
     @property
     def recent_events(self) -> list[GatewayEvent]:
@@ -95,11 +102,28 @@ class EventSubscription:
         self,
         queue: asyncio.Queue[GatewayEvent],
         bus: EventBus,
-        entry: tuple,
+        type_filter: Optional[set[EventType]] = None,
     ):
         self._queue = queue
         self._bus = bus
-        self._entry = entry
+        self.type_filter = type_filter
+        self.dropped = 0  # events lost to queue overflow
+
+    def deliver(self, event: GatewayEvent) -> None:
+        """Enqueue an event, dropping the oldest on overflow."""
+        try:
+            self._queue.put_nowait(event)
+        except asyncio.QueueFull:
+            try:
+                self._queue.get_nowait()
+                self._queue.put_nowait(event)
+            except (asyncio.QueueEmpty, asyncio.QueueFull):
+                pass
+            self.dropped += 1
+            if self.dropped in (1, 10, 100) or self.dropped % 1000 == 0:
+                logger.warning(
+                    f"📡 Slow subscriber: {self.dropped} events dropped"
+                )
 
     def __aiter__(self):
         return self
@@ -108,7 +132,7 @@ class EventSubscription:
         try:
             return await self._queue.get()
         except asyncio.CancelledError:
-            self._bus.unsubscribe(self._entry)
+            self._bus.unsubscribe(self)
             raise
 
     async def get(self, timeout: Optional[float] = None) -> GatewayEvent:
@@ -117,4 +141,4 @@ class EventSubscription:
 
     def close(self):
         """Unsubscribe from the event bus."""
-        self._bus.unsubscribe(self._entry)
+        self._bus.unsubscribe(self)

core/gateway.py

@@ -33,13 +33,28 @@ def build_sip_engine(
     on_device_registered: Callable,
     on_incoming_call: Callable,
 ) -> SIPEngine:
-    """Build the appropriate SIP engine from config."""
+    """
+    Build the SIP engine from config.
+
+    The mock engine must be requested explicitly (USE_MOCK_SIP=true).
+    An unconfigured trunk or a failed SippyEngine construction raises —
+    the caller fails startup rather than running a gateway that can't
+    place real calls while reporting healthy.
+    """
+    if settings.use_mock_sip:
+        logger.warning("🧪 USE_MOCK_SIP=true — SIP engine is a mock, no real calls")
+        return MockSIPEngine()
+
     trunk = settings.sip_trunk
     gw_sip = settings.gateway_sip
 
-    if trunk.host and trunk.host != "sip.provider.com":
-        # Real trunk configured — use Sippy B2BUA
-        try:
+    if not trunk.host or trunk.host in ("sip.provider.com", "sip.yourprovider.com"):
+        raise RuntimeError(
+            "SIP trunk is not configured (SIP_TRUNK_HOST is unset or a "
+            "placeholder). Set SIP_TRUNK_* in .env, or set USE_MOCK_SIP=true "
+            "for development without a trunk."
+        )
+
     return SippyEngine(
         sip_address=gw_sip.host,
         sip_port=gw_sip.port,
@@ -55,10 +70,6 @@ def build_sip_engine(
         on_device_registered=on_device_registered,
         on_incoming_call=on_incoming_call,
     )
-        except Exception as e:
-            logger.warning(f"Could not create SippyEngine: {e} — using mock")
-
-    return MockSIPEngine()
 
 
 class AIPSTNGateway:

core/sippy_engine.py

@@ -50,7 +50,6 @@ class SipCallLeg:
         self.state = "init"  # init, trying, ringing, connected, terminated
         self.media_port: Optional[int] = None  # PJSUA2 conf bridge port
         self.pending_sdp: Optional[str] = None  # inbound INVITE SDP, until answered
-        self.dtmf_buffer: list[str] = []
 
     def __repr__(self):
         return f"<SipCallLeg {self.leg_id} {self.direction} {self.state} → {self.remote_uri}>"
@@ -297,9 +296,8 @@ class SippyEngine(SIPEngine):
             ]
 
         elif kind == "dtmf":
-            leg = self._legs.get(data["leg_id"])
-            if leg:
-                leg.dtmf_buffer.append(data["digit"])
+            # Received DTMF has no consumer yet; log until one exists
+            logger.info(f"  DTMF '{data['digit']}' received on {data['leg_id']}")
 
         elif kind == "trunk_registered":
             self._trunk_registered = data["registered"]

db/database.py

@@ -85,24 +85,6 @@ class StoredCallFlow(Base):
         return f"<StoredCallFlow {self.id} {self.phone_number}>"
 
 
-class Contact(Base):
-    __tablename__ = "contacts"
-
-    id = Column(String, primary_key=True)
-    name = Column(String, nullable=False)
-    phone_numbers = Column(JSON, nullable=False)  # [{number, label, primary}, ...]
-    category = Column(String)  # personal / business / service
-    routing_preference = Column(String, nullable=True)  # how to handle their calls
-    notes = Column(Text, nullable=True)
-    call_count = Column(Integer, default=0)
-    last_call = Column(DateTime, nullable=True)
-    created_at = Column(DateTime, default=func.now())
-    updated_at = Column(DateTime, default=func.now(), onupdate=func.now())
-
-    def __repr__(self) -> str:
-        return f"<Contact {self.id} {self.name}>"
-
-
 class Device(Base):
     __tablename__ = "devices"
 

main.py

@@ -172,6 +172,7 @@ async def lifespan(app: FastAPI):
 
         gateway.register_mode_handler(CallMode.HOLD_SLAYER, launch_hold_slayer)
 
+        try:
             gateway.sip_engine = build_sip_engine(
                 settings,
                 gateway.media_pipeline,
@@ -179,11 +180,15 @@ async def lifespan(app: FastAPI):
                 on_device_registered=gateway._on_sip_device_registered,
                 on_incoming_call=receptionist.on_inbound_call,
             )
+        except Exception as e:
+            logger.critical(f"\n❌  SIP engine failed to initialize:\n    {e}")
+            sys.exit(1)
 
         await routing_svc.start()
         await gateway.start()
         app.state.gateway = gateway
         app.state.routing_service = routing_svc
+        app.state.transcription_service = transcription
 
         notification_svc = NotificationService(gateway.event_bus, settings)
         await notification_svc.start()
@@ -298,21 +303,67 @@ async def root():
 
 @app.get("/health", tags=["System"])
 async def health():
-    """Health check endpoint."""
+    """
+    Health check. "healthy" means the gateway can actually do its job:
+    real engine, registered trunk, reachable database. A mock engine or
+    a failing dependency reports "degraded" with the reason visible.
+    """
+    from core.sip_engine import MockSIPEngine
+    from db.database import session_scope
+
     gateway = getattr(app.state, "gateway", None)
     ready = gateway is not None and await gateway.sip_engine.is_ready()
     trunk_status = await gateway.sip_engine.get_trunk_status() if gateway else {"registered": False}
-    return {
-        "status": "healthy" if ready else "degraded",
+    engine_mode = (
+        "mock" if gateway is None or isinstance(gateway.sip_engine, MockSIPEngine)
+        else "sippy"
+    )
+
+    db_ok = False
+    db_error = None
+    try:
+        from sqlalchemy import text
+        async with session_scope() as session:
+            await session.execute(text("SELECT 1"))
+        db_ok = True
+    except Exception as e:
+        db_error = str(e)[:200]
+
+    healthy = (
+        ready
+        and db_ok
+        and engine_mode == "sippy"
+        and trunk_status.get("registered", False)
+    )
+
+    checks = {
         "gateway": "ready" if gateway else "not initialized",
+        "engine": engine_mode,
         "sip_engine": "ready" if ready else "not ready",
+        "database": "ok" if db_ok else f"error: {db_error}",
         "sip_trunk": {
             "registered": trunk_status.get("registered", False),
             "host": trunk_status.get("host"),
-            "mock": trunk_status.get("mock", False),
             "reason": trunk_status.get("reason"),
         },
     }
+    if gateway is not None:
+        tts = getattr(gateway, "_tts", None)
+        checks["tts"] = _availability(tts)
+        transcription = getattr(app.state, "transcription_service", None)
+        checks["stt"] = _availability(transcription)
+
+    return {"status": "healthy" if healthy else "degraded", **checks}
+
+
+def _availability(service) -> str:
+    """Last-known reachability of an HTTP leaf service."""
+    if service is None:
+        return "not attached"
+    available = getattr(service, "available", None)
+    if available is None:
+        return "unknown (no requests yet)"
+    return "ok" if available else "unreachable"
 
 
 if __name__ == "__main__":

models/contact.py

@@ -1,60 +0,0 @@
-"""
-Contact models — People and organizations you call.
-"""
-
-from datetime import datetime
-from typing import Optional
-
-from pydantic import BaseModel, Field
-
-
-class PhoneNumber(BaseModel):
-    """A phone number associated with a contact."""
-
-    number: str  # E.164 format
-    label: str = "main"  # main, mobile, work, home, fax, etc.
-    primary: bool = False
-
-
-class ContactBase(BaseModel):
-    """Shared contact fields."""
-
-    name: str
-    phone_numbers: list[PhoneNumber]
-    category: Optional[str] = None  # personal / business / service
-    routing_preference: Optional[str] = None  # how to handle their calls
-    notes: Optional[str] = None
-
-
-class Contact(ContactBase):
-    """Full contact model."""
-
-    id: str
-    call_count: int = 0
-    last_call: Optional[datetime] = None
-    created_at: Optional[datetime] = None
-    updated_at: Optional[datetime] = None
-
-    @property
-    def primary_number(self) -> Optional[str]:
-        """Get the primary phone number."""
-        for pn in self.phone_numbers:
-            if pn.primary:
-                return pn.number
-        return self.phone_numbers[0].number if self.phone_numbers else None
-
-
-class ContactCreate(ContactBase):
-    """Request model for creating a contact."""
-
-    pass
-
-
-class ContactUpdate(BaseModel):
-    """Request model for updating a contact."""
-
-    name: Optional[str] = None
-    phone_numbers: Optional[list[PhoneNumber]] = None
-    category: Optional[str] = None
-    routing_preference: Optional[str] = None
-    notes: Optional[str] = None

services/call_persistence.py

@@ -7,6 +7,7 @@ surfaces can't drift. Every function takes an AsyncSession; callers
 own the transaction (get_db for REST, session_scope for MCP/services).
 """
 
+import asyncio
 import logging
 import uuid
 from datetime import datetime
@@ -159,9 +160,25 @@ async def persist_call_on_end(call: ActiveCall, final_status: CallStatus) -> Non
     """Insert a CallRecord and any transcript chunks for `call`.
 
     Wired into CallManager as its on_call_ended hook by the
-    composition root in main.py.
+    composition root in main.py. Retries briefly — losing the row
+    means the call never happened as far as history is concerned, so
+    the final failure logs at ERROR with the payload identifiers.
     """
+    for attempt in range(3):
         try:
+            await _write_call_record(call, final_status)
+            return
+        except Exception as e:
+            if attempt == 2:
+                logger.error(
+                    f"Call record lost: id={call.id} number={call.remote_number} "
+                    f"status={final_status.value}: {e}"
+                )
+                return
+            await asyncio.sleep(2**attempt)
+
+
+async def _write_call_record(call: ActiveCall, final_status: CallStatus) -> None:
     async with session_scope() as session:
         record = CallRecord(
             id=call.id,
@@ -207,5 +224,3 @@ async def persist_call_on_end(call: ActiveCall, final_status: CallStatus) -> Non
                 speaker=speaker,
                 text=payload,
             ))
-    except Exception as e:
-        logger.warning(f"Could not persist call {call.id}: {e}")

services/hold_slayer.py

@@ -56,6 +56,29 @@ class HoldSlayerService:
         self.settings = settings
         self.tts = tts
 
+    async def _service_error(self, call_id: str, service: str, error: Exception) -> None:
+        """Surface a failed dependency as a typed event, not silence."""
+        logger.error(f"⚠️ {service} failed for {call_id}: {error}")
+        try:
+            await self.gateway.event_bus.publish(GatewayEvent(
+                type=EventType.ERROR,
+                call_id=call_id,
+                data={"service": service, "error": str(error)},
+                message=f"⚠️ {service} failed: {error}",
+            ))
+        except Exception:
+            pass
+
+    async def _transcribe(
+        self, call_id: str, audio: bytes, prompt: Optional[str] = None
+    ) -> str:
+        """Transcribe with an explicit empty-string fallback on failure."""
+        try:
+            return await self.transcription.transcribe(audio, prompt=prompt)
+        except Exception as e:
+            await self._service_error(call_id, "transcription", e)
+            return ""
+
     async def run(
         self,
         call: ActiveCall,
@@ -309,9 +332,10 @@ class HoldSlayerService:
                 AudioClassification.IVR_PROMPT,
                 AudioClassification.LIVE_HUMAN,
             ):
-                transcript = await self.transcription.transcribe(
+                transcript = await self._transcribe(
+                    call.id,
                     audio_chunk,
-                    prompt="Phone IVR menu, customer service, press 1 for..."
+                    prompt="Phone IVR menu, customer service, press 1 for...",
                 )
                 if transcript:
                     await self.call_manager.add_transcript(call.id, transcript)
@@ -429,7 +453,7 @@ class HoldSlayerService:
             # Check for human
             if result.audio_type == AudioClassification.LIVE_HUMAN:
                 # Verify with transcription
-                transcript = await self.transcription.transcribe(audio_chunk)
+                transcript = await self._transcribe(call.id, audio_chunk)
                 if transcript:
                     await self.call_manager.add_transcript(call.id, transcript)
                     # If we got meaningful speech, it's probably a real person
@@ -491,7 +515,7 @@ class HoldSlayerService:
                 continue
 
             # Transcribe
-            transcript = await self.transcription.transcribe(audio_chunk)
+            transcript = await self._transcribe(call.id, audio_chunk)
             if not transcript:
                 continue
 
@@ -545,7 +569,7 @@ class HoldSlayerService:
                 AudioClassification.IVR_PROMPT,
                 AudioClassification.LIVE_HUMAN,
             ):
-                text = await self.transcription.transcribe(audio_chunk)
+                text = await self._transcribe(call.id, audio_chunk)
                 if text:
                     transcript_parts.append(text)
 
@@ -712,8 +736,12 @@ class HoldSlayerService:
         fd, tmp_path = tempfile.mkstemp(suffix=".wav", prefix=f"speak_{call.id}_")
         os.close(fd)
 
+        try:
             try:
                 ok = await self.tts.synthesize_to_file(text, tmp_path)
+            except Exception as e:
+                await self._service_error(call.id, "tts", e)
+                return False
             if not ok:
                 logger.warning(f"🗣️ TTS synthesis returned no audio for: '{text[:60]}'")
                 return False

services/llm_client.py

@@ -327,15 +327,14 @@ class LLMClient:
         except httpx.HTTPStatusError as e:
             self._total_errors += 1
             logger.error(f"LLM API error: {e.response.status_code} {e.response.text[:200]}")
-            return ""
+            raise
         except httpx.TimeoutException:
             self._total_errors += 1
             logger.error(f"LLM API timeout after {self.timeout}s")
-            return ""
-        except Exception as e:
+            raise
+        except Exception:
             self._total_errors += 1
-            logger.error(f"LLM client error: {e}")
-            return ""
+            raise
 
     @staticmethod
     def _parse_json_response(text: str) -> dict[str, Any]:

services/notification.py

@@ -67,7 +67,6 @@ class NotificationService:
         self._event_bus = event_bus
         self._settings = settings
         self._task: Optional[asyncio.Task] = None
-        self._sms_sender: Optional[Any] = None
 
         # Track what we've already notified (avoid spam)
         self._notified: dict[str, set[str]] = {}  # call_id -> set of event types
@@ -214,43 +213,3 @@ class NotificationService:
 
         # WebSocket notifications go through the event bus
         # (the WebSocket handler in the API reads from EventBus directly)
-
-        # SMS for critical notifications
-        if (
-            notification.priority == NotificationPriority.CRITICAL
-            and self._settings.notify_sms_number
-        ):
-            await self._send_sms(notification)
-
-    async def _send_sms(self, notification: Notification) -> None:
-        """
-        Send an SMS notification.
-
-        Uses a simple HTTP-based SMS gateway. In production,
-        this would use Twilio, AWS SNS, or similar.
-        """
-        phone = self._settings.notify_sms_number
-        if not phone:
-            return
-
-        try:
-            import httpx
-
-            # Generic webhook-based SMS (configure your provider)
-            # This is a placeholder — wire up your preferred SMS provider
-            logger.info(f"📱 SMS → {phone}: {notification.title}")
-
-            # Example: Twilio-style API
-            # async with httpx.AsyncClient() as client:
-            #     await client.post(
-            #         "https://api.twilio.com/2010-04-01/Accounts/.../Messages.json",
-            #         data={
-            #             "To": phone,
-            #             "From": self._settings.sip_trunk.did,
-            #             "Body": f"{notification.title}\n{notification.message}",
-            #         },
-            #         auth=(account_sid, auth_token),
-            #     )
-
-        except Exception as e:
-            logger.error(f"SMS send failed: {e}")

services/receptionist.py

@@ -203,6 +203,19 @@ class ReceptionistService:
     # State machine steps
     # ----------------------------------------------------------------
 
+    async def _service_error(self, call_id: str, service: str, error: Exception) -> None:
+        """Surface a failed dependency as a typed event, not silence."""
+        logger.error(f"⚠️ {service} failed for {call_id}: {error}")
+        try:
+            await self.gateway.event_bus.publish(GatewayEvent(
+                type=EventType.ERROR,
+                call_id=call_id,
+                data={"service": service, "error": str(error)},
+                message=f"⚠️ {service} failed: {error}",
+            ))
+        except Exception:
+            pass
+
     async def _greet(self, call: ActiveCall, sip_leg_id: str) -> None:
         await self.gateway.event_bus.publish(GatewayEvent(
             type=EventType.RECEPTIONIST_GREETING,
@@ -250,7 +263,11 @@ class ReceptionistService:
         if not audio or self.transcription is None:
             return ""
 
+        try:
             return await self.transcription.transcribe(bytes(audio))
+        except Exception as e:
+            await self._service_error(call.id, "transcription", e)
+            return ""
 
     async def _classify(
         self,
@@ -291,7 +308,7 @@ class ReceptionistService:
                 system=self.settings.llm_persona,
             )
         except Exception as e:
-            logger.warning(f"Receptionist LLM classify failed: {e}")
+            await self._service_error(call.id, "llm", e)
             return {
                 "intent": transcript,
                 "urgency": "normal",
@@ -304,10 +321,14 @@ class ReceptionistService:
         routing_decision: Optional[RoutingDecision],
         classification: dict,
     ) -> RoutingAction:
-        """Rules win on conflict; otherwise use the LLM's recommendation."""
-        if routing_decision and routing_decision.action.type not in (
-            RoutingActionType.TAKE_MESSAGE,
-        ):
+        """Rules win on conflict; otherwise use the LLM's recommendation.
+
+        A decision counts as a rule only when one actually matched
+        (matched_rule_id set) — the no-rule default is take_message and
+        must stay overridable by the LLM. A matched TAKE_MESSAGE rule
+        wins like any other rule.
+        """
+        if routing_decision and routing_decision.matched_rule_id:
             return routing_decision.action
 
         recommended = (classification.get("recommended_action") or "ring").lower()
@@ -347,7 +368,13 @@ class ReceptionistService:
             call.id, media_pipeline=media, leg_ids=[sip_leg_id]
         )
         try:
-            await asyncio.sleep(self.settings.message_max_seconds)
+            # Record up to the cap, but stop early once the caller hangs
+            # up (leg termination ends the call via the leg-state wiring).
+            deadline = _time.monotonic() + self.settings.message_max_seconds
+            while _time.monotonic() < deadline:
+                await asyncio.sleep(1.0)
+                if self.gateway.call_manager.get_call(call.id) is None:
+                    break
         finally:
             session = await recording_svc.stop_recording(
                 call.id, media_pipeline=media
@@ -360,7 +387,7 @@ class ReceptionistService:
                     audio_bytes = Path(rec_path).read_bytes()
                     message_text = await self.transcription.transcribe(audio_bytes)
                 except Exception as e:
-                logger.warning(f"Receptionist transcribe failed: {e}")
+                    await self._service_error(call.id, "transcription", e)
 
             if message_text:
                 call.transcript_chunks.append(f"caller_message: {message_text}")
@@ -393,8 +420,12 @@ class ReceptionistService:
 
         fd, tmp_path = tempfile.mkstemp(suffix=".wav", prefix=f"recept_{call.id}_")
         os.close(fd)
+        try:
             try:
                 ok = await tts.synthesize_to_file(text, tmp_path)
+            except Exception as e:
+                await self._service_error(call.id, "tts", e)
+                return
             if not ok:
                 return
             await media.play_wav(sip_leg_id, tmp_path)

services/recording.py

@@ -91,6 +91,7 @@ class RecordingService:
             filepath_agent=filepath_agent,
             started_at=datetime.now(),
             sample_rate=self._sample_rate,
+            leg_ids=leg_ids,
         )
 
         # Start PJSUA2 recording if media pipeline is available
@@ -159,12 +160,18 @@ class RecordingService:
 
     @staticmethod
     async def _persist_recording(session: "RecordingSession") -> None:
-        """Write a recordings row for this session. Failures are non-fatal."""
-        try:
-            import uuid as _uuid
-            from db.database import RecordingRecord, get_session_factory
+        """Write a recordings row for this session, with bounded retry.
 
-            async with get_session_factory()() as db:
+        Non-fatal for the call, but a lost row means the dashboard can
+        never find the WAV — so failures log at ERROR, not warning.
+        """
+        import uuid as _uuid
+
+        from db.database import RecordingRecord, session_scope
+
+        for attempt in range(3):
+            try:
+                async with session_scope() as db:
                     db.add(RecordingRecord(
                         id=f"rec_{_uuid.uuid4().hex[:10]}",
                         call_id=session.call_id,
@@ -176,9 +183,15 @@ class RecordingService:
                         started_at=session.started_at,
                         ended_at=session.stopped_at,
                     ))
-                await db.commit()
+                return
             except Exception as e:
-            logger.warning(f"Recording persistence failed: {e}")
+                if attempt == 2:
+                    logger.error(
+                        f"Recording row lost for {session.call_id} "
+                        f"(path={session.filepath_mixed}): {e}"
+                    )
+                    return
+                await asyncio.sleep(2 ** attempt)
 
     async def _recording_timeout(self, call_id: str) -> None:
         """Auto-stop recording after max duration."""
@@ -239,6 +252,7 @@ class RecordingSession:
         filepath_agent: Optional[str] = None,
         started_at: Optional[datetime] = None,
         sample_rate: int = 16000,
+        leg_ids: Optional[list[str]] = None,
     ):
         self.call_id = call_id
         self.filepath_mixed = filepath_mixed
@@ -249,7 +263,7 @@ class RecordingSession:
         self.duration_seconds: Optional[int] = None
         self.file_size_bytes: Optional[int] = None
         self.sample_rate = sample_rate
-        self._leg_ids: list[str] = []
+        self._leg_ids: list[str] = list(leg_ids or [])
 
     def to_dict(self) -> dict:
         return {

services/transcription.py

@@ -27,6 +27,8 @@ class TranscriptionService:
     def __init__(self, settings: SpeachesSettings):
         self.settings = settings
         self._client: Optional[httpx.AsyncClient] = None
+        # Last-known reachability, surfaced by /health (None = no requests yet)
+        self.available: Optional[bool] = None
 
     async def _get_client(self) -> httpx.AsyncClient:
         """Get or create the HTTP client."""
@@ -60,6 +62,9 @@ class TranscriptionService:
         # Convert raw PCM to WAV format for the API
         wav_data = self._pcm_to_wav(audio_data)
 
+        # Raises on failure — callers decide the per-call fallback and
+        # publish a service-error event; swallowing here made a down
+        # Speaches look like "the AI is deciding badly".
         try:
             response = await client.post(
                 "/v1/audio/transcriptions",
@@ -72,45 +77,14 @@ class TranscriptionService:
                 },
             )
             response.raise_for_status()
+        except Exception:
+            self.available = False
+            raise
+        self.available = True
         text = response.text.strip()
         logger.debug(f"Transcription: '{text}'")
         return text
 
-        except httpx.HTTPStatusError as e:
-            logger.error(f"Speaches API error: {e.response.status_code} {e.response.text}")
-            return ""
-        except httpx.ConnectError:
-            logger.error(f"Cannot connect to Speaches at {self.settings.url}")
-            return ""
-        except Exception as e:
-            logger.error(f"Transcription failed: {e}")
-            return ""
-
-    async def transcribe_stream(
-        self,
-        audio_data: bytes,
-        language: str = "en",
-    ):
-        """
-        Stream transcription — for real-time results.
-
-        Uses Speaches streaming endpoint if available,
-        falls back to chunked transcription.
-
-        Yields:
-            str: Partial transcription chunks
-        """
-        # For now, do chunked transcription
-        # TODO: Implement WebSocket streaming when Speaches supports it
-        chunk_size = 16000 * 2 * 3  # 3 seconds of 16kHz 16-bit mono
-
-        for i in range(0, len(audio_data), chunk_size):
-            chunk = audio_data[i:i + chunk_size]
-            if len(chunk) > 0:
-                text = await self.transcribe(chunk, language)
-                if text:
-                    yield text
-
     async def close(self) -> None:
         """Close the HTTP client."""
         if self._client and not self._client.is_closed:

services/tts.py

@@ -22,6 +22,8 @@ class TTSService:
     def __init__(self, settings: TTSSettings):
         self.settings = settings
         self._client: Optional[httpx.AsyncClient] = None
+        # Last-known reachability, surfaced by /health (None = no requests yet)
+        self.available: Optional[bool] = None
 
     async def _get_client(self) -> httpx.AsyncClient:
         if self._client is None or self._client.is_closed:
@@ -54,19 +56,17 @@ class TTSService:
             "sample_rate": self.settings.sample_rate,
         }
 
+        # Raises on failure — callers decide the per-call fallback and
+        # publish a service-error event; swallowing here made a down
+        # Rhema look like "the AI went quiet".
         try:
             response = await client.post("/v1/audio/speech", json=body)
             response.raise_for_status()
+        except Exception:
+            self.available = False
+            raise
+        self.available = True
         return response.content
-        except httpx.HTTPStatusError as e:
-            logger.error(f"Rhema TTS error: {e.response.status_code} {e.response.text}")
-            return b""
-        except httpx.ConnectError:
-            logger.error(f"Cannot connect to Rhema at {self.settings.base_url}")
-            return b""
-        except Exception as e:
-            logger.error(f"TTS synthesis failed: {e}")
-            return b""
 
     async def synthesize_to_file(
         self,

tests/test_concurrency.py

@@ -102,14 +102,9 @@ class TestEngineEventFunnel:
 
     async def test_dtmf_and_trunk_events(self):
         engine = _engine_on_loop()
-        _post_from_thread(engine, "incoming_invite", {
-            "leg_id": "leg_test4", "from_uri": "a", "to_uri": "b", "sdp": None,
-        })
-        await asyncio.sleep(0.05)
         _post_from_thread(engine, "dtmf", {"leg_id": "leg_test4", "digit": "5"})
         _post_from_thread(engine, "trunk_registered", {"registered": True})
         await asyncio.sleep(0.05)
-        assert engine._legs["leg_test4"].dtmf_buffer == ["5"]
         assert engine._trunk_registered is True
 
 

tests/test_health_policy.py

@@ -0,0 +1,89 @@
+"""
+Engine-mode and event-bus-integrity tests.
+
+The mock engine must be requested explicitly; a full subscriber queue
+drops its oldest event but never loses the subscription; history is
+replayable to late joiners.
+"""
+
+import asyncio
+
+import pytest
+
+from config import Settings
+from core.event_bus import EventBus
+from core.gateway import build_sip_engine
+from core.media_pipeline import MediaPipeline
+from core.sip_engine import MockSIPEngine
+from models.events import EventType, GatewayEvent
+
+
+def _noop(*args, **kwargs):
+    pass
+
+
+class TestEngineMode:
+    def _build(self, settings: Settings):
+        return build_sip_engine(
+            settings,
+            MediaPipeline(sample_rate=16000),
+            on_leg_state_change=_noop,
+            on_device_registered=_noop,
+            on_incoming_call=_noop,
+        )
+
+    def test_mock_engine_only_when_asked(self):
+        settings = Settings(use_mock_sip=True)
+        assert isinstance(self._build(settings), MockSIPEngine)
+
+    def test_unconfigured_trunk_refuses_to_build(self):
+        settings = Settings(use_mock_sip=False)
+        settings.sip_trunk.host = "sip.yourprovider.com"
+        with pytest.raises(RuntimeError, match="not configured"):
+            self._build(settings)
+
+
+def _event(i: int) -> GatewayEvent:
+    return GatewayEvent(
+        type=EventType.CALL_INITIATED,
+        call_id=f"call_{i}",
+        data={},
+        message=f"event {i}",
+    )
+
+
+class TestEventBusIntegrity:
+    async def test_overflow_drops_oldest_keeps_subscription(self):
+        bus = EventBus()
+        sub = bus.subscribe(max_size=3)
+
+        for i in range(5):
+            await bus.publish(_event(i))
+
+        assert bus.subscriber_count == 1  # never evicted
+        assert sub.dropped == 2
+        received = [await asyncio.wait_for(sub.get(), 1.0) for _ in range(3)]
+        assert [e.call_id for e in received] == ["call_2", "call_3", "call_4"]
+
+    async def test_replay_last_seeds_history(self):
+        bus = EventBus()
+        for i in range(10):
+            await bus.publish(_event(i))
+
+        sub = bus.subscribe(replay_last=3)
+        received = [await asyncio.wait_for(sub.get(), 1.0) for _ in range(3)]
+        assert [e.call_id for e in received] == ["call_7", "call_8", "call_9"]
+
+    async def test_replay_respects_type_filter(self):
+        bus = EventBus()
+        await bus.publish(_event(1))
+        await bus.publish(GatewayEvent(
+            type=EventType.HUMAN_DETECTED, call_id="call_h", data={}, message="x"
+        ))
+
+        sub = bus.subscribe(
+            event_types={EventType.HUMAN_DETECTED}, replay_last=5
+        )
+        event = await asyncio.wait_for(sub.get(), 1.0)
+        assert event.call_id == "call_h"
+        assert sub._queue.empty()

tests/test_receptionist.py

@@ -24,10 +24,27 @@ class TestReceptionistDecide:
         gw = _make_gateway()
         svc = ReceptionistService(gw)
         rule_action = RoutingAction(type=RoutingActionType.REJECT, message="nope")
-        decision = RoutingDecision(action=rule_action, reason="rule said so")
+        decision = RoutingDecision(
+            action=rule_action,
+            matched_rule_id="rule_1",
+            matched_rule_name="block",
+            reason="rule said so",
+        )
         chosen = svc._decide(decision, {"recommended_action": "ring"})
         assert chosen.type == RoutingActionType.REJECT
 
+    def test_matched_take_message_rule_beats_llm(self):
+        gw = _make_gateway()
+        svc = ReceptionistService(gw)
+        decision = RoutingDecision(
+            action=RoutingAction(type=RoutingActionType.TAKE_MESSAGE),
+            matched_rule_id="rule_2",
+            matched_rule_name="voicemail-hours",
+            reason="matched rule 'voicemail-hours'",
+        )
+        chosen = svc._decide(decision, {"recommended_action": "ring"})
+        assert chosen.type == RoutingActionType.TAKE_MESSAGE
+
     def test_falls_back_to_llm_when_rule_is_default_take_message(self):
         gw = _make_gateway()
         svc = ReceptionistService(gw)

tests/test_services.py

@@ -123,14 +123,14 @@ class TestLLMClient:
             assert result["key"] == "value"
 
     @pytest.mark.asyncio
-    async def test_chat_http_error_returns_empty(self):
-        """Verify HTTP errors return empty string gracefully."""
+    async def test_chat_error_raises(self):
+        """Failures propagate to the caller (which owns the fallback)."""
         client = self._make_client()
 
         with patch.object(client._client, "post", new_callable=AsyncMock) as mock_post:
             mock_post.side_effect = Exception("Connection refused")
-            result = await client.chat("test", system="test")
-            assert result == ""
+            with pytest.raises(Exception, match="Connection refused"):
+                await client.chat("test", system="test")
             assert client._total_errors == 1
 
     @pytest.mark.asyncio