hyperion-rb 2.16.1 → 2.16.2

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data/CHANGELOG.md

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 # Changelog
 
+## 2.16.2 — 2026-05-04
+
+### 2.16.2-A — macOS Obj-C fork-safety: re-exec, not just ENV write
+
+**Why.** 2.16.1's `ENV['OBJC_DISABLE_INITIALIZE_FORK_SAFETY'] ||= 'YES'`
+in `bin/hyperion` and `lib/hyperion.rb` did not actually stop the
+crash. The Obj-C runtime caches that env var's value at **dyld init**
+— before any Ruby code runs. By the time `bin/hyperion`'s first
+line executes, the runtime has already decided whether the post-fork
+check fires. Setting the var from Ruby is observable to `ENV.fetch`
+and inherited by `Process.fork` children via the kernel's env
+duplication, but the Obj-C runtime's own check ignores the late
+write. Workers continued to crash on `+[NSCharacterSet initialize]`
+in fork children after a 2.16.1 master spawned them.
+
+**What 2.16.2-A ships.** `bin/hyperion` now **re-execs itself** with
+the env var set when launched on `darwin` without it:
+
+```ruby
+if RUBY_PLATFORM.include?('darwin') && ENV['OBJC_DISABLE_INITIALIZE_FORK_SAFETY'].nil?
+  ENV['OBJC_DISABLE_INITIALIZE_FORK_SAFETY'] = 'YES'
+  exec(RbConfig.ruby, __FILE__, *ARGV)
+end
+```
+
+`exec` replaces the current process image; dyld of the new image
+reads `OBJC_DISABLE_INITIALIZE_FORK_SAFETY=YES` from the inherited
+environment and the runtime's fork-safety check honours it for the
+master and every worker forked from it. Operators who have already
+set the var explicitly (shell export, Foreman's `.env` load,
+Dockerfile `ENV`) skip the re-exec — the `nil?` guard preserves
+deliberate `=NO` settings if anyone has a reason for those. The
+operator-facing shell call (`bundle exec hyperion …`) sees a single
+child and a single exit status; the re-exec is invisible.
+
+`lib/hyperion.rb`'s 2.16.1 `ENV ||=` line is removed: it was
+misleading (couldn't work for the current process anyway).
+Programmatic users embedding Hyperion via `require 'hyperion'`
+without `bin/hyperion` on macOS must set the env var themselves in
+the shell or wrapper before launching Ruby — same as before 2.16.1.
+
+**Verification.**
+
+- `bin/check` green.
+- Fresh `bundle exec hyperion -C config/hyperion.rb config.ru` against
+  the same Rails 8.1 app that reproduced the 2.16.1 crash loop:
+  master + workers boot cleanly; no `NSCharacterSet`-init crash; no
+  worker respawn churn; sequential curls return 200 OK.
+
 ## 2.16.1 — 2026-05-04
 
 ### 2.16.1-A — macOS Obj-C fork-safety guard

data/bin/hyperion

@@ -1,14 +1,31 @@
 #!/usr/bin/env ruby
 # frozen_string_literal: true
 
-# 2.16.1 — macOS fork-safety. The Obj-C runtime's post-fork sanity check
-# crashes any worker that touches a Foundation class which was mid-init
-# in the master at fork time (e.g. NSCharacterSet, common as a side-effect
-# of OpenSSL / system-resolver loads). The escape hatch is the env var
-# below; it must be set before Foundation classes load. Set on darwin
-# unconditionally — no-op elsewhere. `||=` so an operator who has set
-# it explicitly (e.g. to `NO`) is honoured.
-ENV['OBJC_DISABLE_INITIALIZE_FORK_SAFETY'] ||= 'YES' if RUBY_PLATFORM.include?('darwin')
+# 2.16.2 — macOS fork-safety. The Obj-C runtime caches the value of
+# `OBJC_DISABLE_INITIALIZE_FORK_SAFETY` at dyld init time, BEFORE any
+# Ruby code runs. Setting `ENV[...]` from Ruby is observable to
+# `Process.fork`'s child via inheritance, but the runtime's own
+# fork-safety check has already locked in its decision based on the
+# env it saw at process launch. So a Ruby-side `ENV[...] = 'YES'`
+# does not stop the post-fork crash:
+#   "+[NSCharacterSet initialize] may have been in progress in another
+#    thread when fork() was called. We cannot safely call it or ignore
+#    it in the fork() child process. Crashing instead."
+#
+# The reliable way to get the var into dyld's view is to re-exec the
+# Ruby process with it set. Once the new process starts, dyld picks
+# up the env var and the runtime's fork-safety check honours it.
+# `exec` replaces the current image so the wrapper shell call (e.g.
+# `bundle exec hyperion …`) sees a single child process and a single
+# exit status — no double accounting from the operator's side.
+#
+# Operators who've already set the var explicitly (in their shell, in
+# Foreman's .env load, in a Dockerfile ENV) skip this re-exec — we
+# only re-exec when the var is unset.
+if RUBY_PLATFORM.include?('darwin') && ENV['OBJC_DISABLE_INITIALIZE_FORK_SAFETY'].nil?
+  ENV['OBJC_DISABLE_INITIALIZE_FORK_SAFETY'] = 'YES'
+  exec(RbConfig.ruby, __FILE__, *ARGV)
+end
 
 $LOAD_PATH.unshift(File.expand_path('../lib', __dir__))
 require 'hyperion/cli'

data/lib/hyperion/version.rb

@@ -1,5 +1,5 @@
 # frozen_string_literal: true
 
 module Hyperion
-  VERSION = '2.16.1'
+  VERSION = '2.16.2'
 end

data/lib/hyperion.rb

@@ -1,14 +1,12 @@
 # frozen_string_literal: true
 
-# 2.16.1 — macOS fork-safety. Mirrors the guard at the top of
-# `bin/hyperion` so programmatic `require 'hyperion'` (specs,
-# embedded uses) gets the same workaround. The Obj-C runtime's
-# post-fork check crashes workers that touch a Foundation class
-# which was mid-init in the master at fork time (NSCharacterSet
-# is a frequent victim — it loads transitively via OpenSSL / system
-# resolver paths). `||=` so an operator who has set the var
-# explicitly is honoured. No-op on non-darwin platforms.
-ENV['OBJC_DISABLE_INITIALIZE_FORK_SAFETY'] ||= 'YES' if RUBY_PLATFORM.include?('darwin')
+# Note: macOS Obj-C fork-safety is handled in `bin/hyperion` (re-exec
+# with `OBJC_DISABLE_INITIALIZE_FORK_SAFETY=YES`). It cannot be handled
+# from this file: setting `ENV[...]` from Ruby runs after dyld has
+# already cached its decision, so by the time `require 'hyperion'`
+# fires, the runtime's fork-safety check has locked in. Operators
+# embedding Hyperion programmatically (no `bin/hyperion`) on macOS
+# must set the env var in their shell or wrapper before exec.
 
 require_relative 'hyperion/version'
 require_relative 'hyperion/logger'

metadata

@@ -1,7 +1,7 @@
 --- !ruby/object:Gem::Specification
 name: hyperion-rb
 version: !ruby/object:Gem::Version
-  version: 2.16.1
+  version: 2.16.2
 platform: ruby
 authors:
 - Andrey Lobanov