From 2428afd3db587b11a3060e5c98c82c4c5e47d5f7 Mon Sep 17 00:00:00 2001
From: Corey Johnson <probablycorey@gmail.com>
Date: Wed, 21 Jan 2026 14:54:17 -0800
Subject: [PATCH] Add SIP registration error handling with Twilio API

- Catch all SIP error codes (not just 403) in registration failures
- Query Twilio API on error to get detailed account status
- Show helpful message like "Twilio account suspended - add funds"
- Retry registration after 2 minutes instead of exiting
- Add restart() method to Baresip for clean reconnection

Requires TWILIO_ACCOUNT_SID and TWILIO_AUTH_TOKEN env vars for
detailed error messages.

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
---
 src/phone.ts        | 25 ++++++++++++++++-------
 src/sip.ts          | 21 +++++++++++++++----
 src/utils/twilio.ts | 50 +++++++++++++++++++++++++++++++++++++++++++++
 3 files changed, 85 insertions(+), 11 deletions(-)
 create mode 100644 src/utils/twilio.ts

diff --git a/src/phone.ts b/src/phone.ts
index 0a29c6b..9be461c 100644
--- a/src/phone.ts
+++ b/src/phone.ts
@@ -18,6 +18,7 @@ import GPIO from "./pins"
 import { Agent } from "./agent"
 import { searchWeb } from "./agent/tools"
 import { ring } from "./utils"
+import { getTwilioAccountInfo, formatTwilioError } from "./utils/twilio"
 import { getSound, WaitingSounds } from "./utils/waiting-sounds"
 
 type CancelableTask = () => void
@@ -123,14 +124,24 @@ const startBaresip = async (phoneService: PhoneService, hook: GPIO.Input, ringer
     phoneService.send({ type: "error", message: error.message })
   })
 
-  baresip.error.on(async ({ message }) => {
-    log.error("🐻 error:", message)
-    phoneService.send({ type: "error", message })
-    for (let i = 0; i < 4; i++) {
-      await ring(ringer, 500)
-      await sleep(250)
+  baresip.error.on(async ({ message, statusCode, reason }) => {
+    let errorMessage = message
+
+    if (statusCode) {
+      const twilioInfo = await getTwilioAccountInfo()
+      if (twilioInfo && twilioInfo.status !== "active") {
+        errorMessage = formatTwilioError(twilioInfo)
+      } else {
+        errorMessage = `Registration failed: ${statusCode} ${reason}`
+      }
     }
-    process.exit(1)
+
+    log.error("🐻 error:", errorMessage)
+    // Don't send error to state machine - we're retrying, not giving up
+
+    log("🔄 Retrying registration in 2 minutes...")
+    await sleep(2 * 60 * 1000)
+    baresip.restart()
   })
 
   return baresip
diff --git a/src/sip.ts b/src/sip.ts
index 46c26de..4626d84 100644
--- a/src/sip.ts
+++ b/src/sip.ts
@@ -8,7 +8,7 @@ export class Baresip {
   callEstablished = new Emitter<{ contact: string }>()
   callReceived = new Emitter<{ contact: string }>()
   hungUp = new Emitter()
-  error = new Emitter<{ message: string }>()
+  error = new Emitter<{ message: string; statusCode?: string; reason?: string }>()
   registrationSuccess = new Emitter()
 
   constructor(baresipArgs: string[]) {
@@ -52,6 +52,7 @@ export class Baresip {
     this.callReceived.removeAllListeners()
     this.hungUp.removeAllListeners()
     this.registrationSuccess.removeAllListeners()
+    this.error.removeAllListeners()
   }
 
   kill() {
@@ -61,6 +62,14 @@ export class Baresip {
     this.process = undefined
   }
 
+  async restart() {
+    if (this.process) {
+      this.process.kill()
+      this.process = undefined
+    }
+    await this.connect()
+  }
+
   #parseLine(line: string) {
     log.debug(`📞 Baresip: ${line}`)
     const callEstablishedMatch = line.match(/Call established: (.+)/)
@@ -91,10 +100,14 @@ export class Baresip {
       this.registrationSuccess.emit()
     }
 
-    const registrationFailedMatch = line.match(/reg: sip:\S+ 403 Forbidden/)
+    const registrationFailedMatch = line.match(/reg: sip:\S+ .*?(\d{3}) (\w+)/)
     const socketInUseMatch = line.match(/tcp: sock_bind:/)
-    if (registrationFailedMatch || socketInUseMatch) {
-      log.error(`⁉️ NOT HANDLED: Registration failed with "${line}"`)
+    if (registrationFailedMatch) {
+      const [, statusCode, reason] = registrationFailedMatch
+      log.error(`Registration failed: ${statusCode} ${reason}`)
+      this.error.emit({ message: line, statusCode, reason })
+    } else if (socketInUseMatch) {
+      log.error(`Registration failed: socket in use`)
       this.error.emit({ message: line })
     }
   }
diff --git a/src/utils/twilio.ts b/src/utils/twilio.ts
new file mode 100644
index 0000000..ea95066
--- /dev/null
+++ b/src/utils/twilio.ts
@@ -0,0 +1,50 @@
+const accountSid = process.env.TWILIO_ACCOUNT_SID
+const authToken = process.env.TWILIO_AUTH_TOKEN
+
+type AccountStatus = "active" | "suspended" | "closed"
+
+interface TwilioAccountInfo {
+  status: AccountStatus
+  balance?: string
+  currency?: string
+}
+
+export async function getTwilioAccountInfo(): Promise<TwilioAccountInfo | undefined> {
+  if (!accountSid || !authToken) {
+    return undefined
+  }
+
+  const credentials = Buffer.from(`${accountSid}:${authToken}`).toString("base64")
+  const headers = { Authorization: `Basic ${credentials}` }
+
+  const [accountRes, balanceRes] = await Promise.all([
+    fetch(`https://api.twilio.com/2010-04-01/Accounts/${accountSid}.json`, { headers }),
+    fetch(`https://api.twilio.com/2010-04-01/Accounts/${accountSid}/Balance.json`, { headers }),
+  ])
+
+  if (!accountRes.ok) {
+    return undefined
+  }
+
+  const account = (await accountRes.json()) as { status: AccountStatus }
+  const info: TwilioAccountInfo = { status: account.status }
+
+  if (balanceRes.ok) {
+    const balance = (await balanceRes.json()) as { balance: string; currency: string }
+    info.balance = balance.balance
+    info.currency = balance.currency
+  }
+
+  return info
+}
+
+export function formatTwilioError(info: TwilioAccountInfo): string {
+  if (info.status === "suspended") {
+    const balanceInfo = info.balance ? ` (balance: ${info.balance} ${info.currency})` : ""
+    return `Twilio account suspended${balanceInfo} - add funds at twilio.com/console`
+  }
+  if (info.status === "closed") {
+    return "Twilio account is closed"
+  }
+  return `Twilio account status: ${info.status}`
+}