fix: gate DTW comparisons on wafer type + recording category; surface load errors

tests/test_session_controller.py

@@ -47,6 +47,36 @@ def test_pause_stop_timer(controller):
     controller.stop()
     assert controller.frameIndex == 0
 
+def test_load_file_emits_error_for_empty_recording(controller, tmp_path):
+    """A recording with a valid header but zero data rows (e.g. Record was
+    started/stopped without any live frames arriving) must surface a clear
+    loadFileError instead of silently doing nothing."""
+    empty_recording = tmp_path / "live_A00001_20260706_120427.csv"
+    empty_recording.write_text(
+        "Wafer ID=A00001\n"
+        "Acquisition Date=07/06/2026\n"
+        "Label,1,2\n"
+        "X (mm),0.0,10.0\n"
+        "Y (mm),10.0,-10.0\n"
+        "data\n"
+    )
+
+    mock_slot = MagicMock()
+    controller.loadFileError.connect(mock_slot)
+    controller.loadFile(str(empty_recording))
+
+    assert mock_slot.call_count == 1
+    assert "no recorded frames" in mock_slot.call_args[0][0]
+    assert controller.loadedFile == ""
+
+def test_load_file_switches_to_review_mode(controller):
+    """Loading a file for playback must always land in review mode, even if
+    the controller was left in live mode from a previous session — otherwise
+    a successful load can be invisible behind a stale Live toggle."""
+    controller._mode = "live"
+    controller.loadFile("tests/fixtures/sample_stream.csv")
+    assert controller.mode == "review"
+
 def test_compare_files_integration(controller):
     # Mock the comparisonResult signal
     mock_slot = MagicMock()
@@ -65,6 +95,96 @@ def test_compare_files_integration(controller):
     assert "series_b" in args
     assert args["frame_offset"] == 0
 
+def test_compare_files_uses_full_run_not_first_100_frames(controller, tmp_path):
+    """compareFiles must score the whole run, not just an initial 100-frame window.
+
+    Regression test: max_frames used to be hard-capped at 100, so a >100-frame
+    run's soak/cool phases were silently excluded from the DTW comparison.
+    """
+    num_frames = 150
+    csv_path = tmp_path / "long_run.csv"
+    lines = ["Wafer ID=A12", "Acquisition Date=03/26/2025", "Label,1,2,3",
+             "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data"]
+    for i in range(num_frames):
+        t = i * 0.5
+        lines.append(f"{t},{149.0 + i * 0.01},{148.5 + i * 0.01},{150.6 + i * 0.01}")
+    csv_path.write_text("\n".join(lines) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(csv_path), str(csv_path))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is True
+    assert len(result["series_a"]) == num_frames
+    assert len(result["series_b"]) == num_frames
+
+def test_compare_files_rejects_mismatched_wafer_types(controller, tmp_path):
+    """compareFiles must refuse to compare two different wafer families.
+
+    Otherwise the overlap view silently truncates to min(sensor_count) and
+    pairs up unrelated physical sensors between the two wafer types.
+    """
+    header = ["Wafer ID=A12", "Acquisition Date=03/26/2025", "Label,1,2,3",
+              "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data",
+              "0.0,149.0,148.5,150.6"]
+    file_a = tmp_path / "A00055-20250326.csv"
+    file_b = tmp_path / "X00108-20250326.csv"
+    file_a.write_text("\n".join(header) + "\n")
+    file_b.write_text("\n".join(header) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(file_a), str(file_b))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is False
+    assert "A" in result["error"] and "X" in result["error"]
+
+def test_compare_files_rejects_recording_vs_read_mem(controller, tmp_path):
+    """A live_-prefixed recording must not be compared against a read-memory
+    dump. Regression: stem[0] on "live_P0001_..." is "L", which used to be
+    misreported as a wafer-type mismatch ("L vs P") instead of this clearer
+    recording-vs-read-mem error.
+    """
+    header = ["Wafer ID=P0001", "Acquisition Date=03/26/2025", "Label,1,2,3",
+              "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data",
+              "0.0,149.0,148.5,150.6"]
+    recording = tmp_path / "live_P0001_20260706_143022.csv"
+    read_mem = tmp_path / "P0001-20260706_143500.csv"
+    recording.write_text("\n".join(header) + "\n")
+    read_mem.write_text("\n".join(header) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(recording), str(read_mem))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is False
+    assert result["error"] == "Cannot compare a recording file with a read-memory file"
+
+def test_compare_files_allows_two_recordings_of_same_wafer_type(controller, tmp_path):
+    """Two live recordings of the same wafer family should compare fine —
+    the "live_" prefix must not be mistaken for the wafer type letter."""
+    header = ["Wafer ID=P0001", "Acquisition Date=03/26/2025", "Label,1,2,3",
+              "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data",
+              "0.0,149.0,148.5,150.6"]
+    file_a = tmp_path / "live_P0001_20260706_143022.csv"
+    file_b = tmp_path / "live_P0002_20260706_150000.csv"
+    file_a.write_text("\n".join(header) + "\n")
+    file_b.write_text("\n".join(header) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(file_a), str(file_b))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is True
+
 def test_comparison_result_reaches_qml(qapp, controller):
     """The result dict must arrive in QML as a real JS object with fields.