fix(flow): improve tail capture and final chunk ASR recovery

- Add FlowUtteranceEndCoordinator with 350ms silence drain and 150ms post-roll
- Extend FinalChunkRecovery for short/empty final chunks in chunked pipeline
- Snapshot partial at mic stop and guard final transcript in FlowSessionManager
- Unify tail drain presets (iosFlow/macMLX) and expand diagnostics

Co-authored-by: Rocky <hkgood@users.noreply.github.com>

OSGKeyboardShared/Services/ChunkedUtterancePipeline.swift

@@ -101,6 +101,7 @@ public actor ChunkedUtterancePipeline {
         var processedChunks = 0
         var previousChunkSamples: [Float] = []
         var lastChunkSamples = 0
+        var didRetryEmptyFinal = false
 
         let feeder = Task {
             for await chunk in UtteranceStreamChunker.chunks(from: stream, config: config) {
@@ -118,20 +119,28 @@ public actor ChunkedUtterancePipeline {
 
             guard let chunk = await queue.dequeue() else { break }
 
+            if chunk.isLast && chunk.samples.isEmpty {
+                continue
+            }
+
             processedChunks += 1
             lastChunkSamples = chunk.samples.count
 
-            if chunk.isLast,
-               chunk.samples.count < config.minFinalChunkSamples,
-               processedChunks > 1,
-               !previousChunkSamples.isEmpty {
-                let mergedSamples = Array(previousChunkSamples.suffix(config.overlapSamples))
-                    + chunk.samples
-                let mergedResult = await transcribeChunk(samples: mergedSamples)
+            if let preMerge = FinalChunkRecovery.preMergePlan(
+                chunk: chunk,
+                processedChunks: processedChunks,
+                previousChunkSamples: previousChunkSamples,
+                config: config
+            ) {
+                FlowPipelineDiagnostics.logFinalChunkRecovery(
+                    action: "preMerge",
+                    chunkIndex: chunk.index
+                )
+                let mergedResult = await transcribeChunk(samples: preMerge.samples)
                 switch mergedResult {
                 case .success(let text):
                     stitcher.removeLastSegment()
-                    stitcher.append(index: max(0, chunk.index - 1), text: text)
+                    stitcher.append(index: preMerge.stitchIndex, text: text)
                     publishPartial(from: stitcher, onPartial: onPartial)
                 case .failure(let message):
                     failedChunks += 1
@@ -153,8 +162,52 @@ public actor ChunkedUtterancePipeline {
             let result = await transcribeChunk(samples: chunk.samples)
             switch result {
             case .success(let text):
-                stitcher.append(index: chunk.index, text: text)
-                publishPartial(from: stitcher, onPartial: onPartial)
+                if chunk.isLast,
+                   !didRetryEmptyFinal,
+                   let retry = FinalChunkRecovery.emptyResultRetryPlan(
+                       chunk: chunk,
+                       previousChunkSamples: previousChunkSamples,
+                       config: config,
+                       asrText: text
+                   ) {
+                    didRetryEmptyFinal = true
+                    FlowPipelineDiagnostics.logFinalChunkRecovery(
+                        action: "emptyRetry",
+                        chunkIndex: chunk.index
+                    )
+                    let retryResult = await transcribeChunk(samples: retry.samples)
+                    switch retryResult {
+                    case .success(let retryText):
+                        let trimmed = retryText.trimmingCharacters(in: .whitespacesAndNewlines)
+                        if !trimmed.isEmpty {
+                            if retry.stitchIndex < chunk.index {
+                                stitcher.removeLastSegment()
+                            }
+                            stitcher.append(index: retry.stitchIndex, text: retryText)
+                            publishPartial(from: stitcher, onPartial: onPartial)
+                        } else {
+                            stitcher.append(index: chunk.index, text: text)
+                            publishPartial(from: stitcher, onPartial: onPartial)
+                        }
+                    case .failure(let message):
+                        stitcher.append(index: chunk.index, text: text)
+                        publishPartial(from: stitcher, onPartial: onPartial)
+                        failedChunks += 1
+                        chunkWarnings.append(
+                            SharedL10n.format(
+                                "error.asr.chunkFailed",
+                                chunk.index + 1,
+                                message
+                            )
+                        )
+                    case .cancelled:
+                        feeder.cancel()
+                        return .cancelled
+                    }
+                } else {
+                    stitcher.append(index: chunk.index, text: text)
+                    publishPartial(from: stitcher, onPartial: onPartial)
+                }
             case .failure(let message):
                 failedChunks += 1
                 chunkWarnings.append(

OSGKeyboardShared/Services/FlowContinuousCapture.swift

@@ -666,16 +666,11 @@ public final class FlowContinuousCapture {
         gate.withLock { $0 = .draining }
         drainTracker.beginDrain()
 
-        var endedBySilence = false
-        while true {
-            let decision = drainTracker.shouldFinish(policy: policy)
-            if decision.finished {
-                endedBySilence = decision.endedBySilence
-                break
-            }
-            if Task.isCancelled { break }
-            try? await Task.sleep(nanoseconds: FlowCaptureConstants.drainPollIntervalNs)
-        }
+        let timing = await FlowUtteranceEndCoordinator.awaitTailCapture(
+            tracker: drainTracker,
+            policy: policy,
+            pollIntervalNs: FlowCaptureConstants.drainPollIntervalNs
+        )
 
         // NOTE: We intentionally do NOT signal `.endOfStream` to the shared
         // downsampling converter here. `AVAudioConverter` is stateful: once its
@@ -692,8 +687,9 @@ public final class FlowContinuousCapture {
         let tailSamples = tailSampleCounter.withLock { $0 }
         let report = FlowCaptureDrainReport(
             drainDurationSeconds: drainTracker.elapsedSeconds(),
-            endedBySilence: endedBySilence,
-            tailSampleCount: tailSamples
+            endedBySilence: timing.endedBySilence,
+            tailSampleCount: tailSamples,
+            postRollDurationSeconds: timing.postRollDurationSeconds
         )
         drainTracker.reset()
         tailSampleCounter.withLock { $0 = 0 }

OSGKeyboardShared/Services/LiveDictationController.swift

@@ -558,12 +558,10 @@ public final class LiveDictationController: ObservableObject {
         drainTracker.beginDrain()
 
         let policy = FlowCaptureTailDrainPolicy.flowDefault
-        while true {
-            let decision = drainTracker.shouldFinish(policy: policy)
-            if decision.finished { break }
-            if Task.isCancelled { break }
-            try? await Task.sleep(nanoseconds: 20_000_000)
-        }
+        _ = await FlowUtteranceEndCoordinator.awaitTailCapture(
+            tracker: drainTracker,
+            policy: policy
+        )
 
         // Trailing speech is preserved by the live `.draining` forwarding
         // loop above. We deliberately do NOT signal `.endOfStream` to the

OSGKeyboardShared/Utilities/FinalChunkRecovery.swift

@@ -0,0 +1,47 @@
+// FinalChunkRecovery.swift
+// OSGKeyboard · Shared
+//
+// Recovery plans for pipelined utterance ASR when the final chunk is short,
+// empty, or straddles a chunk boundary.
+
+import Foundation
+
+public enum FinalChunkRecovery {
+
+    /// Samples and stitch index when the final chunk should be merged with
+    /// prior overlap *before* the first ASR pass.
+    public static func preMergePlan(
+        chunk: UtteranceAudioChunk,
+        processedChunks: Int,
+        previousChunkSamples: [Float],
+        config: FlowUtteranceChunkConfig
+    ) -> (samples: [Float], stitchIndex: Int)? {
+        guard chunk.isLast, !chunk.samples.isEmpty, !previousChunkSamples.isEmpty else {
+            return nil
+        }
+        guard chunk.samples.count < config.minFinalChunkSamples else { return nil }
+
+        let merged = Array(previousChunkSamples.suffix(config.overlapSamples)) + chunk.samples
+        return (merged, max(0, chunk.index - 1))
+    }
+
+    /// Retry plan when the final chunk had audio but ASR returned empty text.
+    public static func emptyResultRetryPlan(
+        chunk: UtteranceAudioChunk,
+        previousChunkSamples: [Float],
+        config: FlowUtteranceChunkConfig,
+        asrText: String
+    ) -> (samples: [Float], stitchIndex: Int)? {
+        guard chunk.isLast, !chunk.samples.isEmpty else { return nil }
+        guard asrText.trimmingCharacters(in: .whitespacesAndNewlines).isEmpty else {
+            return nil
+        }
+
+        if previousChunkSamples.isEmpty {
+            return (chunk.samples, chunk.index)
+        }
+
+        let merged = Array(previousChunkSamples.suffix(config.overlapSamples)) + chunk.samples
+        return (merged, max(0, chunk.index - 1))
+    }
+}

OSGKeyboardShared/Utilities/FlowCaptureTailDrain.swift

@@ -16,22 +16,39 @@ public struct FlowCaptureTailDrainPolicy: Sendable, Equatable {
     public let silenceDurationSeconds: TimeInterval
     /// Hard cap so noisy environments cannot stall finalize forever.
     public let maxDrainSeconds: TimeInterval
+    /// Fixed post-roll after silence drain; independent of RMS (captures weak tails).
+    public let postRollSeconds: TimeInterval
 
     public init(
         silenceRMSThreshold: Float,
         silenceDurationSeconds: TimeInterval,
-        maxDrainSeconds: TimeInterval
+        maxDrainSeconds: TimeInterval,
+        postRollSeconds: TimeInterval = 0
     ) {
         self.silenceRMSThreshold = silenceRMSThreshold
         self.silenceDurationSeconds = silenceDurationSeconds
         self.maxDrainSeconds = maxDrainSeconds
+        self.postRollSeconds = postRollSeconds
     }
 
-    public static let flowDefault = FlowCaptureTailDrainPolicy(
+    /// iOS Flow host + keyboard utterance capture.
+    public static let iosFlow = FlowCaptureTailDrainPolicy(
         silenceRMSThreshold: 0.015,
-        silenceDurationSeconds: 0.25,
-        maxDrainSeconds: 1.5
+        silenceDurationSeconds: 0.35,
+        maxDrainSeconds: 1.5,
+        postRollSeconds: 0.15
     )
+
+    /// Mac MLX streaming live capture.
+    public static let macMLX = FlowCaptureTailDrainPolicy(
+        silenceRMSThreshold: 0.015,
+        silenceDurationSeconds: 0.35,
+        maxDrainSeconds: 0.75,
+        postRollSeconds: 0.15
+    )
+
+    /// Backward-compatible alias for iOS Flow defaults.
+    public static let flowDefault = iosFlow
 }
 
 /// Metrics emitted when tail drain completes (for diagnostics and tests).
@@ -39,21 +56,25 @@ public struct FlowCaptureDrainReport: Sendable, Equatable {
     public let drainDurationSeconds: Double
     public let endedBySilence: Bool
     public let tailSampleCount: Int
+    public let postRollDurationSeconds: Double
 
     public init(
         drainDurationSeconds: Double,
         endedBySilence: Bool,
-        tailSampleCount: Int
+        tailSampleCount: Int,
+        postRollDurationSeconds: Double = 0
     ) {
         self.drainDurationSeconds = drainDurationSeconds
         self.endedBySilence = endedBySilence
         self.tailSampleCount = tailSampleCount
+        self.postRollDurationSeconds = postRollDurationSeconds
     }
 
     public static let skipped = FlowCaptureDrainReport(
         drainDurationSeconds: 0,
         endedBySilence: false,
-        tailSampleCount: 0
+        tailSampleCount: 0,
+        postRollDurationSeconds: 0
     )
 }
 

OSGKeyboardShared/Utilities/FlowPipelineDiagnostics.swift

@@ -9,10 +9,22 @@ import os
 public enum FlowPipelineDiagnostics {
     public static func logDrain(_ report: FlowCaptureDrainReport) {
         OSGLog.flow.info(
-            "tailDrain duration=\(report.drainDurationSeconds, format: .fixed(precision: 2))s silenceEnd=\(report.endedBySilence) tailSamples=\(report.tailSampleCount)"
+            "tailDrain duration=\(report.drainDurationSeconds, format: .fixed(precision: 2))s " +
+            "postRoll=\(report.postRollDurationSeconds, format: .fixed(precision: 2))s " +
+            "silenceEnd=\(report.endedBySilence) tailSamples=\(report.tailSampleCount)"
         )
     }
 
+    public static func logTranscriptGuardUsedPartial(finalLength: Int, partialLength: Int) {
+        OSGLog.flow.warning(
+            "transcriptGuard partial preferred finalLen=\(finalLength) partialLen=\(partialLength)"
+        )
+    }
+
+    public static func logFinalChunkRecovery(action: String, chunkIndex: Int) {
+        OSGLog.asr.info("finalChunkRecovery \(action) chunk=\(chunkIndex)")
+    }
+
     public static func logChunkFinalize(
         chunkCount: Int,
         lastChunkSamples: Int,

OSGKeyboardShared/Utilities/FlowUtteranceEndCoordinator.swift

@@ -0,0 +1,66 @@
+// FlowUtteranceEndCoordinator.swift
+// OSGKeyboard · Shared
+//
+// Unified tail-drain + post-roll orchestration after the user stops recording.
+// Keeps the mic gate open through silence detection, then a fixed post-roll
+// window that does not depend on RMS (captures weak trailing syllables).
+
+import Foundation
+
+/// Outcome of `FlowUtteranceEndCoordinator.awaitTailCapture`.
+public struct FlowUtteranceEndTiming: Sendable, Equatable {
+    public let endedBySilence: Bool
+    public let postRollDurationSeconds: Double
+
+    public init(endedBySilence: Bool, postRollDurationSeconds: Double) {
+        self.endedBySilence = endedBySilence
+        self.postRollDurationSeconds = postRollDurationSeconds
+    }
+}
+
+public enum FlowUtteranceEndCoordinator {
+    /// Poll interval while waiting for silence / max drain (20 ms).
+    public static let pollIntervalNs: UInt64 = 20_000_000
+
+    /// Waits until trailing speech drains (silence or max cap), then sleeps
+    /// through a fixed post-roll window so weak tail audio still reaches ASR.
+    ///
+    /// Callers must keep forwarding PCM from the audio tap while this runs
+    /// (gate `.draining` or equivalent).
+    public static func awaitTailCapture(
+        tracker: FlowCaptureDrainTracker,
+        policy: FlowCaptureTailDrainPolicy,
+        pollIntervalNs: UInt64 = pollIntervalNs
+    ) async -> FlowUtteranceEndTiming {
+        var endedBySilence = false
+        while true {
+            let decision = tracker.shouldFinish(policy: policy)
+            if decision.finished {
+                endedBySilence = decision.endedBySilence
+                break
+            }
+            if Task.isCancelled { break }
+            try? await Task.sleep(nanoseconds: pollIntervalNs)
+        }
+
+        let postRoll = await runPostRoll(policy: policy, pollIntervalNs: pollIntervalNs)
+        return FlowUtteranceEndTiming(
+            endedBySilence: endedBySilence,
+            postRollDurationSeconds: postRoll
+        )
+    }
+
+    private static func runPostRoll(
+        policy: FlowCaptureTailDrainPolicy,
+        pollIntervalNs: UInt64
+    ) async -> Double {
+        guard policy.postRollSeconds > 0 else { return 0 }
+        let started = Date()
+        let deadline = started.addingTimeInterval(policy.postRollSeconds)
+        while Date() < deadline {
+            if Task.isCancelled { break }
+            try? await Task.sleep(nanoseconds: pollIntervalNs)
+        }
+        return max(0, Date().timeIntervalSince(started))
+    }
+}

OSGKeyboardShared/Utilities/UtteranceStreamChunker.swift

@@ -56,7 +56,11 @@ public enum UtteranceStreamChunker {
                 } else if chunkIndex == 0 {
                     // Empty utterance — no chunks.
                 } else {
-                    // Stream ended exactly on boundary; mark prior path complete.
+                    // Stream ended exactly on a chunk boundary; prior emit holds
+                    // all tail audio. Marker so FinalChunkRecovery paths run.
+                    continuation.yield(
+                        UtteranceAudioChunk(index: chunkIndex, samples: [], isLast: true)
+                    )
                 }
 
                 continuation.finish()

OSGKeyboardShared/Utilities/UtteranceTranscriptGuard.swift

@@ -0,0 +1,35 @@
+// UtteranceTranscriptGuard.swift
+// OSGKeyboard · Shared
+//
+// Chooses the best available transcript when pipelined final text may have
+// dropped a weak tail segment.
+
+import Foundation
+
+public enum UtteranceTranscriptGuard {
+    /// Partial must exceed final by at least this many characters to win.
+    public static let defaultPartialAdvantage = 8
+
+    /// Prefer `stitchedFinal` unless empty or clearly shorter than the live
+    /// partial snapshot taken at mic stop.
+    public static func resolve(
+        stitchedFinal: String,
+        partialSnapshot: String,
+        minimumPartialAdvantage: Int = defaultPartialAdvantage
+    ) -> String {
+        let final = stitchedFinal.trimmingCharacters(in: .whitespacesAndNewlines)
+        let partial = partialSnapshot.trimmingCharacters(in: .whitespacesAndNewlines)
+
+        if final.isEmpty { return partial }
+        if partial.isEmpty { return final }
+
+        if partial.count >= final.count + minimumPartialAdvantage {
+            FlowPipelineDiagnostics.logTranscriptGuardUsedPartial(
+                finalLength: final.count,
+                partialLength: partial.count
+            )
+            return partial
+        }
+        return final
+    }
+}