Fix settings overflow, icon cache color bug, and chart perf (#105)

* fix: wrap popover content in ScrollView to prevent settings overflow

When settings sections are expanded, the content can exceed the 700px
panel max height, pushing the header (with gear/close button) off-screen
and making it impossible to close settings. Wrapping the middle content
in a ScrollView keeps header and footer pinned while allowing the
scrollable area to handle overflow gracefully.

* fix: include color in MenuBarIcon cache key, consolidate chart onChange

MenuBarIcon cache keyed only on quantized percent + pulse step, so
switching metric modes at the same percent (e.g. rate limit vs context
health at 75%) could return the wrong cached color. Adding color hash
to the key prevents stale icon colors on mode switch.

ActivityChartView had 3 separate onChange handlers that all fired on
the same snapshot update, causing redundant O(n) chart transforms.
Consolidated into a single dataFingerprint computed property.

* ci: tolerate Swift Testing runner crash-on-shutdown

Swift Testing on macOS 15 can SIGABRT/SIGSEGV during test runner
teardown even when all tests pass. Check output for actual test
failures instead of relying solely on exit code.

* fix: scope ScrollView to settings only, restore dynamic panel sizing

The full-content ScrollView broke panel height calculation — ScrollView
reports a large fittingSize regardless of content, preventing the panel
from shrinking when sections collapse. Scope the ScrollView to just the
SettingsRow (capped at 350pt) so the rest of the content drives
fittingSize naturally and the panel resizes correctly.

* ci: guard against empty test suite in crash-tolerant runner

---------

Co-authored-by: KyleNesium <22541778+KyleNesium@users.noreply.github.com>

Author: KyleNesium

.github/workflows/ci.yml

@@ -45,7 +45,27 @@ jobs:
         run: swift build
 
       - name: Run tests
-        run: swift test --skip-build
+        run: |
+          # Swift Testing on macOS 15 can crash during runner shutdown (signal 6/11)
+          # even when all tests pass. Capture output and check for actual test failures.
+          set +e
+          swift test --skip-build 2>&1 | tee test-output.txt
+          exit_code=$?
+          set -e
+          if grep -q '✘ Test' test-output.txt; then
+            echo "Test failures detected"
+            exit 1
+          fi
+          if grep -q 'error: build' test-output.txt; then
+            echo "Build errors detected"
+            exit 1
+          fi
+          passed=$(grep -c '✔ Test' test-output.txt || true)
+          if [ "$passed" -eq 0 ]; then
+            echo "No tests passed — something is wrong"
+            exit 1
+          fi
+          echo "All $passed tests passed (exit code was $exit_code)"
 
       - name: Verify app bundle
         run: |

AIBattery/Views/ActivityChartView.swift

@@ -50,6 +50,16 @@ struct ActivityChartView: View {
         }
     }
 
+    /// Single fingerprint combining all data sources — collapses 3 onChange handlers into 1.
+    /// When any underlying data changes, the fingerprint changes, triggering one refresh.
+    private var dataFingerprint: Int {
+        var hasher = Hasher()
+        hasher.combine(dailyActivity.count)
+        hasher.combine(snapshot?.totalMessages)
+        hasher.combine(todayHourCounts.values.reduce(0, +))
+        return hasher.finalize()
+    }
+
     /// Check source data directly — avoids recomputing chart data just for an emptiness check.
     private var isEmpty: Bool {
         switch mode {
@@ -127,9 +137,7 @@ struct ActivityChartView: View {
         .padding(.horizontal, 16)
         .padding(.vertical, 8)
         .onAppear { refreshCachedData() }
-        .onChange(of: dailyActivity.count) { _ in refreshCachedData() }
-        .onChange(of: snapshot?.totalMessages) { _ in refreshCachedData() }
-        .onChange(of: todayHourCounts.values.reduce(0, +)) { _ in refreshCachedData() }
+        .onChange(of: dataFingerprint) { _ in refreshCachedData() }
         .onChange(of: modeRaw) { _ in ensureCachedData(for: mode) }
     }
 

AIBattery/Views/MenuBarIcon.swift

@@ -70,17 +70,18 @@ struct MenuBarIcon: View {
         return Int((clamped / 5).rounded(.down)) * 5
     }
 
-    /// Composite cache key: quantized percent × 100 + pulseStep for normal,
-    /// 10_100 + pulseStep for broken, 10_200 + pulseStep for sparkle.
-    /// Max entries: 21×8 + 8 + 8 = 184.
-    static func cacheKey(quantizedPercent: Int, isBroken: Bool, isSparkle: Bool, pulseStep: Int) -> Int {
+    /// Composite cache key incorporating percent, color, state, and pulse step.
+    /// Color hash distinguishes the same percent across metric modes
+    /// (e.g. rate limit green vs context health yellow at 75%).
+    /// Max entries: 21×8 + 8 + 8 = 184 per color variant.
+    static func cacheKey(quantizedPercent: Int, colorHash: Int, isBroken: Bool, isSparkle: Bool, pulseStep: Int) -> Int {
         if isBroken {
-            return 10_100 + pulseStep
+            return 10_100 + pulseStep + colorHash &* 100_000
         }
         if isSparkle {
-            return 10_200 + pulseStep
+            return 10_200 + pulseStep + colorHash &* 100_000
         }
-        return quantizedPercent * 100 + pulseStep
+        return quantizedPercent * 100 + pulseStep + colorHash &* 100_000
     }
 
     // MARK: - Icon cache
@@ -133,6 +134,7 @@ struct MenuBarIcon: View {
         let currentColorblind = ThemeColors.isColorblind
 
         // Check cache under lock; render outside lock to avoid holding it during image creation
+        let colorHash = color.hash
         let (key, cached, highContrast, isDarkMode): (Int, NSImage?, Bool, Bool) = cacheLock.withLock {
             if cachedColorblindFlag != currentColorblind
                 || cachedAppearanceName != appearanceName {
@@ -142,7 +144,7 @@ struct MenuBarIcon: View {
             }
 
             let qPercent = quantizedPercent(percent)
-            let k = cacheKey(quantizedPercent: qPercent, isBroken: isBroken, isSparkle: isSparkle, pulseStep: pulseStep)
+            let k = cacheKey(quantizedPercent: qPercent, colorHash: colorHash, isBroken: isBroken, isSparkle: isSparkle, pulseStep: pulseStep)
             let hc = cachedHighContrastFlag
             let dm = currentAppearance?.bestMatch(from: [.darkAqua, .aqua]) == .darkAqua
             return (k, iconCache[k], hc, dm)

AIBattery/Views/UsagePopoverView.swift

@@ -63,11 +63,17 @@ public struct UsagePopoverView: View {
             Divider()
 
             if showSettings {
-                SettingsRow(
-                    viewModel: viewModel,
-                    accountStore: accountStore,
-                    onAddAccount: { isAddingAccount = true }
-                )
+                // Settings in its own ScrollView with capped height so it doesn't
+                // push main content off-screen when all sections are visible.
+                ScrollView {
+                    SettingsRow(
+                        viewModel: viewModel,
+                        accountStore: accountStore,
+                        onAddAccount: { isAddingAccount = true }
+                    )
+                }
+                .scrollIndicators(.automatic)
+                .frame(maxHeight: 350)
                 .transition(.opacity.combined(with: .move(edge: .top)))
                 Divider()
             }

Tests/AIBatteryCoreTests/Utilities/MenuBarIconTests.swift

@@ -52,49 +52,52 @@ struct MenuBarIconTests {
     // MARK: - Cache key
 
     @Test func cacheKey_normalDistinctFromBroken() {
-        let normalKey = MenuBarIcon.cacheKey(quantizedPercent: 50, isBroken: false, isSparkle: false, pulseStep: 0)
-        let brokenKey = MenuBarIcon.cacheKey(quantizedPercent: 50, isBroken: true, isSparkle: false, pulseStep: 0)
+        let normalKey = MenuBarIcon.cacheKey(quantizedPercent: 50, colorHash: 0, isBroken: false, isSparkle: false, pulseStep: 0)
+        let brokenKey = MenuBarIcon.cacheKey(quantizedPercent: 50, colorHash: 0, isBroken: true, isSparkle: false, pulseStep: 0)
         #expect(normalKey != brokenKey)
     }
 
     @Test func cacheKey_normalEncodesPulseStep() {
-        let step0 = MenuBarIcon.cacheKey(quantizedPercent: 50, isBroken: false, isSparkle: false, pulseStep: 0)
-        let step3 = MenuBarIcon.cacheKey(quantizedPercent: 50, isBroken: false, isSparkle: false, pulseStep: 3)
+        let step0 = MenuBarIcon.cacheKey(quantizedPercent: 50, colorHash: 0, isBroken: false, isSparkle: false, pulseStep: 0)
+        let step3 = MenuBarIcon.cacheKey(quantizedPercent: 50, colorHash: 0, isBroken: false, isSparkle: false, pulseStep: 3)
         #expect(step0 != step3)
     }
 
     @Test func cacheKey_differentPercentsAreDistinct() {
-        let key0 = MenuBarIcon.cacheKey(quantizedPercent: 0, isBroken: false, isSparkle: false, pulseStep: 0)
-        let key50 = MenuBarIcon.cacheKey(quantizedPercent: 50, isBroken: false, isSparkle: false, pulseStep: 0)
+        let key0 = MenuBarIcon.cacheKey(quantizedPercent: 0, colorHash: 0, isBroken: false, isSparkle: false, pulseStep: 0)
+        let key50 = MenuBarIcon.cacheKey(quantizedPercent: 50, colorHash: 0, isBroken: false, isSparkle: false, pulseStep: 0)
         #expect(key0 != key50)
     }
 
     @Test func cacheKey_brokenPulseStepsAreDistinct() {
-        let step0 = MenuBarIcon.cacheKey(quantizedPercent: 0, isBroken: true, isSparkle: false, pulseStep: 0)
-        let step4 = MenuBarIcon.cacheKey(quantizedPercent: 0, isBroken: true, isSparkle: false, pulseStep: 4)
-        let step7 = MenuBarIcon.cacheKey(quantizedPercent: 0, isBroken: true, isSparkle: false, pulseStep: 7)
+        let step0 = MenuBarIcon.cacheKey(quantizedPercent: 0, colorHash: 0, isBroken: true, isSparkle: false, pulseStep: 0)
+        let step4 = MenuBarIcon.cacheKey(quantizedPercent: 0, colorHash: 0, isBroken: true, isSparkle: false, pulseStep: 4)
+        let step7 = MenuBarIcon.cacheKey(quantizedPercent: 0, colorHash: 0, isBroken: true, isSparkle: false, pulseStep: 7)
         #expect(step0 != step4)
         #expect(step4 != step7)
-        #expect(step0 == 10_100)
-        #expect(step7 == 10_107)
     }
 
     @Test func cacheKey_noCollisionAt100Percent() {
         // 100% normal and broken must not collide (was a bug with *10 + 1000 base)
         for step in 0..<MenuBarIcon.pulseSteps {
-            let normalKey = MenuBarIcon.cacheKey(quantizedPercent: 100, isBroken: false, isSparkle: false, pulseStep: step)
-            let brokenKey = MenuBarIcon.cacheKey(quantizedPercent: 100, isBroken: true, isSparkle: false, pulseStep: step)
+            let normalKey = MenuBarIcon.cacheKey(quantizedPercent: 100, colorHash: 0, isBroken: false, isSparkle: false, pulseStep: step)
+            let brokenKey = MenuBarIcon.cacheKey(quantizedPercent: 100, colorHash: 0, isBroken: true, isSparkle: false, pulseStep: step)
             #expect(normalKey != brokenKey)
         }
     }
 
     @Test func cacheKey_sparkleDistinctFromNormalAndBroken() {
-        let normalKey = MenuBarIcon.cacheKey(quantizedPercent: 0, isBroken: false, isSparkle: false, pulseStep: 0)
-        let brokenKey = MenuBarIcon.cacheKey(quantizedPercent: 0, isBroken: true, isSparkle: false, pulseStep: 0)
-        let sparkleKey = MenuBarIcon.cacheKey(quantizedPercent: 0, isBroken: false, isSparkle: true, pulseStep: 0)
+        let normalKey = MenuBarIcon.cacheKey(quantizedPercent: 0, colorHash: 0, isBroken: false, isSparkle: false, pulseStep: 0)
+        let brokenKey = MenuBarIcon.cacheKey(quantizedPercent: 0, colorHash: 0, isBroken: true, isSparkle: false, pulseStep: 0)
+        let sparkleKey = MenuBarIcon.cacheKey(quantizedPercent: 0, colorHash: 0, isBroken: false, isSparkle: true, pulseStep: 0)
         #expect(normalKey != sparkleKey)
         #expect(brokenKey != sparkleKey)
-        #expect(sparkleKey == 10_200)
+    }
+
+    @Test func cacheKey_differentColorsAreDistinct() {
+        let greenKey = MenuBarIcon.cacheKey(quantizedPercent: 75, colorHash: 42, isBroken: false, isSparkle: false, pulseStep: 0)
+        let orangeKey = MenuBarIcon.cacheKey(quantizedPercent: 75, colorHash: 99, isBroken: false, isSparkle: false, pulseStep: 0)
+        #expect(greenKey != orangeKey)
     }
 
     // MARK: - Star geometry