Improve 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

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

src/phone.ts

@@ -16,8 +16,9 @@ import Buzz from "./buzz"
 import { join } from "path"
 import GPIO from "./pins"
 import { Agent } from "./agent"
-import { searchWeb } from "./agent/tools"
+import { searchWeb, vestaboard } from "./agent/tools"
 import { ring } from "./utils"
+import { getTwilioAccountInfo, formatTwilioError } from "./utils/twilio"
 import { getSound, WaitingSounds } from "./utils/waiting-sounds"
 
 type CancelableTask = () => void
@@ -47,7 +48,6 @@ export const runPhone = async (agentId: string, agentKey: string) => {
   using rotaryNumber = gpio.input(23, { pull: "up", debounce: 3 })
 
   await Buzz.setVolume(0.3)
-  log(`📞 Phone is ${hook.value ? "off hook" : "on hook"}`)
 
   playStartRing(ringer)
 
@@ -71,7 +71,6 @@ const listenForPhoneEvents = (
 ) => {
   hook.onChange((event) => {
     const type = event.value == 0 ? "hang-up" : "pick-up"
-    log(`📞 Hook ${event.value} sending ${type}`)
     phoneService.send({ type })
   })
 
@@ -95,7 +94,7 @@ const startBaresip = async (phoneService: PhoneService, hook: GPIO.Input, ringer
   const baresip = new Baresip(["/usr/bin/baresip", "-v", "-f", baresipConfig])
 
   baresip.registrationSuccess.on(async () => {
-    log("🐻 server connected")
+    log.debug("🐻 server connected")
     if (hook.value === 0) {
       phoneService.send({ type: "initialized" })
     } else {
@@ -104,17 +103,17 @@ const startBaresip = async (phoneService: PhoneService, hook: GPIO.Input, ringer
   })
 
   baresip.callReceived.on(({ contact }) => {
-    log(`🐻 incoming call from ${contact}`)
+    log.debug(`🐻 incoming call from ${contact}`)
     phoneService.send({ type: "incoming-call", from: contact })
   })
 
   baresip.callEstablished.on(({ contact }) => {
-    log(`🐻 call established with ${contact}`)
+    log.debug(`🐻 call established with ${contact}`)
     phoneService.send({ type: "answered" })
   })
 
   baresip.hungUp.on(() => {
-    log("🐻 call hung up")
+    log.debug("🐻 call hung up")
     phoneService.send({ type: "remote-hang-up" })
   })
 
@@ -123,14 +122,29 @@ const startBaresip = async (phoneService: PhoneService, hook: GPIO.Input, ringer
     phoneService.send({ type: "error", message: error.message })
   })
 
-  baresip.error.on(async ({ message }) => {
+  baresip.error.on(async ({ message, statusCode, reason }) => {
-    log.error("🐻 error:", message)
+    let errorMessage = message
-    phoneService.send({ type: "error", message })
+
+    if (statusCode) {
+      const twilioInfo = await getTwilioAccountInfo()
+      if (twilioInfo && twilioInfo.status !== "active") {
+        errorMessage = formatTwilioError(twilioInfo)
+      } else {
+        errorMessage = `Registration failed: ${statusCode} ${reason}`
+      }
+    }
+
+    log.error("🐻 error:", errorMessage)
+    phoneService.send({ type: "error", message: errorMessage })
+
     for (let i = 0; i < 4; i++) {
       await ring(ringer, 500)
       await sleep(250)
     }
-    process.exit(1)
+
+    log("🔄 Retrying registration in 2 minutes...")
+    await sleep(2 * 60 * 1000)
+    baresip.restart()
   })
 
   return baresip
@@ -173,6 +187,7 @@ const startAgent = (service: Service<typeof phoneMachine>, ctx: PhoneContext) =>
     apiKey: ctx.agentKey,
     tools: {
       search_web: (args: { query: string }) => searchWeb(args.query),
+      vestaboard: (args: { query: string }) => vestaboard(args.query),
     },
   })
 
@@ -298,6 +313,8 @@ const handleAgentEvents = (
 
       case "error":
         log.error("🤖 Agent error:", event.error)
+        streamPlayback?.stop()
+        service.send({ type: "remote-hang-up" })
         break
 
       case "ping":
@@ -322,7 +339,6 @@ const incomingCall = (ctx: PhoneContext, event: { type: "incoming-call"; from?:
 }
 
 const hangUp = (ctx: PhoneContext) => {
-  console.log(`📞 Hanging up call`)
   ctx.baresip.hangUp()
 }
 
@@ -389,19 +405,12 @@ const digitIncrement = (ctx: PhoneContext) => {
 }
 
 const playStartRing = async (ringer: GPIO.Output) => {
-  // Three quick beeps, getting faster = energetic/welcoming
   ringer.value = 1
-  await Bun.sleep(80)
+  await Bun.sleep(500)
   ringer.value = 0
-  await Bun.sleep(120)
+  await Bun.sleep(500)
-
   ringer.value = 1
-  await Bun.sleep(80)
+  await Bun.sleep(1000)
-  ringer.value = 0
-  await Bun.sleep(100)
-
-  ringer.value = 1
-  await Bun.sleep(80)
   ringer.value = 0
 }
 
@@ -454,5 +463,5 @@ const phoneMachine = createMachine(
 )
 
 d._onEnter = function (machine, to, state, prevState, event) {
-  log(`📱 ${machine.current} -> ${to} (${(event as any).type})`)
+  log.debug(`📱 ${machine.current} -> ${to} (${(event as any).type})`)
 }

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) {
+    if (registrationFailedMatch) {
-      log.error(`⁉️ NOT HANDLED: Registration failed with "${line}"`)
+      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 })
     }
   }

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}`
+}