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starpilot/common/starpilot_variables.py

@@ -583,7 +583,7 @@ class StarPilotVariables:
       self.params.put_float("SteerDelay", full_stock_delay)
     self.params.put_bool(STEER_DELAY_MODE_MIGRATION_KEY, True)
 
-  def update(self, holiday_theme="stock", started=False):
+  def update(self, holiday_theme="stock", started=False, clear_update_flag=True):
     toggle = self.starpilot_toggles
     toggle.tuning_level = self.params.get("TuningLevel") if self.params.get_bool("TuningLevelConfirmed") else TUNING_LEVELS["ADVANCED"]
     # CarParams uses this value to select the matching Panda safety configuration.
@@ -1446,4 +1446,5 @@ class StarPilotVariables:
     toggle.volt_sng = self.get_value("VoltSNG", condition=toggle.car_model in LEGACY_VOLT_STOCK_ACC_CARS)
 
     process_starpilot_toggles.cache_clear()
-    self.params_memory.remove("StarPilotTogglesUpdated")
+    if clear_update_flag:
+      self.params_memory.remove("StarPilotTogglesUpdated")

starpilot/common/tests/test_starpilot_process.py

@@ -27,6 +27,40 @@ class FakeModelManager:
     return None
 
 
+def test_background_toggle_update_does_not_mutate_active_toggles():
+  active_toggles = SimpleNamespace(holiday_themes=False, random_themes=False, enabled=False)
+
+  class FakeVariables:
+    def __init__(self):
+      self.starpilot_toggles = active_toggles
+      self.clear_update_flag = None
+
+    def update(self, holiday_theme, started, clear_update_flag=True):
+      self.clear_update_flag = clear_update_flag
+      self.starpilot_toggles.enabled = True
+
+  theme_manager = FakeThemeManager()
+  theme_manager.holiday_theme = "stock"
+  theme_manager.theme_updated = False
+  result = {}
+
+  starpilot_process.update_toggles_in_background(
+    result,
+    FakeVariables(),
+    True,
+    theme_manager,
+    FakeThreadManager(),
+    False,
+    FakeParams(),
+    active_toggles,
+  )
+
+  updated_variables, updated_toggles = result["update"]
+  assert active_toggles.enabled is False
+  assert updated_toggles.enabled is True
+  assert updated_variables.clear_update_flag is False
+
+
 def test_transition_offroad_skips_invalid_gps_persist():
   params = FakeParams()
   planner = SimpleNamespace(gps_position={

starpilot/starpilot_process.py

@@ -1,4 +1,5 @@
 #!/usr/bin/env python3
+import copy
 import datetime
 import hashlib
 import importlib
@@ -209,11 +210,12 @@ def update_checks(now, model_manager, theme_manager, thread_manager, params, par
 
   time.sleep(1)
 
-def update_toggles(starpilot_variables, started, theme_manager, thread_manager, time_validated, params, starpilot_toggles):
+def update_toggles(starpilot_variables, started, theme_manager, thread_manager, time_validated, params, starpilot_toggles,
+                   clear_update_flag=True):
   previous_holiday_themes = starpilot_toggles.holiday_themes
   previous_random_themes = starpilot_toggles.random_themes
 
-  starpilot_variables.update(theme_manager.holiday_theme, started)
+  starpilot_variables.update(theme_manager.holiday_theme, started, clear_update_flag=clear_update_flag)
   starpilot_toggles = starpilot_variables.starpilot_toggles
 
   randomize_theme = starpilot_toggles.holiday_themes != previous_holiday_themes
@@ -224,6 +226,20 @@ def update_toggles(starpilot_variables, started, theme_manager, thread_manager,
 
   return starpilot_toggles
 
+
+def update_toggles_in_background(result, starpilot_variables, started, theme_manager, thread_manager, time_validated, params,
+                                 starpilot_toggles):
+  """Reload toggles without mutating the values used by the planner mid-update."""
+  try:
+    updated_variables = copy.copy(starpilot_variables)
+    updated_variables.starpilot_toggles = copy.copy(starpilot_toggles)
+    updated_toggles = update_toggles(updated_variables, started, theme_manager, thread_manager, time_validated, params,
+                                     updated_variables.starpilot_toggles, clear_update_flag=False)
+    result["update"] = (updated_variables, updated_toggles)
+  except Exception:
+    result["failed"] = True
+    raise
+
 def starpilot_thread():
   rate_keeper = Ratekeeper(1 / DT_MDL, None)
 
@@ -249,6 +265,7 @@ def starpilot_thread():
   starpilot_toggles = starpilot_variables.starpilot_toggles
   serialized_starpilot_toggles = serialize_starpilot_toggles(starpilot_toggles)
   toggle_broadcast_pending = True
+  toggle_update_result = {}
 
   drive_stats_session = requests.Session()
   next_dashboard_analysis_refresh = 0.0
@@ -355,8 +372,9 @@ def starpilot_thread():
     elif current_safe_mode and (params_memory.get_bool("StarPilotTogglesUpdated") or rate_keeper.frame % SAFE_MODE_ENFORCE_FRAMES == 0):
       apply_safe_mode(params, params_raw, params_memory, ensure_backup=False)
 
-    if params_memory.get_bool("StarPilotTogglesUpdated") or theme_manager.theme_updated:
-      starpilot_toggles = update_toggles(starpilot_variables, started, theme_manager, thread_manager, time_validated, params, starpilot_toggles)
+    completed_toggle_update = toggle_update_result.pop("update", None)
+    if completed_toggle_update is not None:
+      starpilot_variables, starpilot_toggles = completed_toggle_update
       serialized_starpilot_toggles = serialize_starpilot_toggles(starpilot_toggles)
       toggle_broadcast_pending = True
 
@@ -365,6 +383,22 @@ def starpilot_thread():
         model_manager.randomize_selected_model()
       model_randomizer_previously = model_randomizer_enabled
 
+    toggle_update_result.pop("failed", None)
+    toggle_refresh_requested = params_memory.get_bool("StarPilotTogglesUpdated") or theme_manager.theme_updated
+    toggle_update_running = thread_manager.is_thread_alive("update_toggles_in_background")
+    if started and toggle_refresh_requested and not toggle_update_running and not toggle_update_result:
+      # StarPilotVariables.update performs hundreds of param reads and can exceed
+      # the starpilotPlan liveness timeout. Keep that work off the planner loop.
+      params_memory.remove("StarPilotTogglesUpdated")
+      thread_manager.run_with_lock(
+        update_toggles_in_background,
+        (toggle_update_result, starpilot_variables, started, theme_manager, thread_manager, time_validated, params, starpilot_toggles),
+      )
+    elif not started and toggle_refresh_requested:
+      starpilot_toggles = update_toggles(starpilot_variables, started, theme_manager, thread_manager, time_validated, params, starpilot_toggles)
+      serialized_starpilot_toggles = serialize_starpilot_toggles(starpilot_toggles)
+      toggle_broadcast_pending = True
+
     periodic_update_due = monotonic_now >= next_periodic_update_check
     if periodic_update_due:
       next_periodic_update_check = get_next_periodic_update_check(monotonic_now, periodic_update_phase)