fix(blastware_file, server): enhance logging and correct chunk handling for accurate data processing

minimateplus/blastware_file.py

@@ -639,6 +639,15 @@ def write_blastware_file(
         strt = b"STRT" + b"\xff\xfe" + key4 + bytes(14) + bytes([rectime & 0xFF])
         probe_skip = 7 + 21
 
+    log.warning(
+        "write_blastware_file: strt_pos_stripped=%d  probe_skip=%d  "
+        "probe_data_len=%d  strt_hex=%s",
+        strt_pos_stripped if strt_pos_stripped >= 0 else -1,
+        probe_skip,
+        len(a5_frames[0].data),
+        strt.hex() if len(strt) >= 4 else "(short)",
+    )
+
     if len(strt) != 21:
         raise ValueError(f"STRT record must be 21 bytes, got {len(strt)}")
 
@@ -701,13 +710,30 @@ def write_blastware_file(
             #     truncated file that Blastware rejects.
             skip = 13 if fi == 1 else 12
 
-        all_bytes.extend(_frame_body_bytes(frame, skip))
+        contribution = _frame_body_bytes(frame, skip)
+        log.warning("write_blastware_file: fi=%d skip=%d raw_data=%d contribution=%d",
+                    fi, skip, len(frame.data), len(contribution))
+        all_bytes.extend(contribution)
 
     # Terminator contributes its content, which ends with the 26-byte footer.
     # skip=11 (not 12) because the terminator's inner frame header is 4 bytes,
     # one shorter than chunk frames' 5-byte inner header.  Confirmed 2026-04-21.
     if term_frame is not None:
-        all_bytes.extend(_frame_body_bytes(term_frame, 11))
+        term_contribution = _frame_body_bytes(term_frame, 11)
+        log.warning(
+            "write_blastware_file: term_frame data_len=%d  skip=11  "
+            "contribution_len=%d  first8=%s",
+            len(term_frame.data),
+            len(term_contribution),
+            term_contribution[:8].hex() if len(term_contribution) >= 8 else term_contribution.hex(),
+        )
+        all_bytes.extend(term_contribution)
+
+    log.warning(
+        "write_blastware_file: all_bytes total=%d  last28=%s",
+        len(all_bytes),
+        bytes(all_bytes[-28:]).hex() if len(all_bytes) >= 28 else bytes(all_bytes).hex(),
+    )
 
     if len(all_bytes) >= 26:
         body   = bytes(all_bytes[:-26])

sfm/server.py

@@ -885,21 +885,22 @@ def device_event_blastware_file(
         def _do():
             with _build_client(port, baud, host, tcp_port, timeout=120.0) as client:
                 info = client.connect()
-                # Use stop_after_metadata=True (full_waveform=False) with 1 extra
+                # Use stop_after_metadata=True (full_waveform=False) with 0 extra
-                # chunk after "Project:".  For any record time, the pre-metadata
+                # chunks after "Project:".  Confirmed from 4-26-26 BW RS-232 capture
-                # section of the 5A stream naturally carries proportionally more
+                # of "copy event to file" on a 2-sec Continuous event (key=01110000):
-                # ADC data for longer events — so "1 extra chunk" produces the
+                # BW sends the termination frame IMMEDIATELY after the chunk that
-                # correct body length regardless of record time.
+                # contains "Project:" — no extra chunk is downloaded first.
+                # extra_chunks_after_metadata=1 was WRONG: it downloaded one additional
+                # chunk (counter = last_data_counter + 0x0400) adding ~1053 spurious
+                # bytes to the body, causing Blastware to reject the file.
                 #
                 # full_waveform=True (natural end-of-stream) downloads ALL chunks
                 # including post-event silence (35+ chunks for a 9-sec event at
                 # 1024 sps) — this produces 24KB+ files that Blastware rejects.
-                # Confirmed from file size comparison: BW 1-sec=4400B, BW 3-sec=8114B,
-                # per-second delta 1857 bytes — matches pre-metadata frame scaling.
                 events = client.get_events(
                     full_waveform=False,
                     stop_after_index=index,
-                    extra_chunks_after_metadata=1,
+                    extra_chunks_after_metadata=0,
                 )
                 matching = [ev for ev in events if ev.index == index]
                 return matching[0] if matching else None, info