Fix Buffer size setting never being applied; add Safety Switch control type

- Buffer size (samples) in Settings > Acquisition was captured into the
  settings dict but never read anywhere — SignalBuffer always used the
  hardcoded MAX_BUFFER=20_000 constant (which happens to match the
  dialog's default, hence it looking like the value "reverts"). Add
  AcquisitionEngine.set_buffer_size(), wired in on startup and on Settings
  apply; existing buffers are rebuilt at the new size in place, keeping
  their most recent samples.

- New "Safety Switch" control type: an On/Off Switch that's disabled
  outright until acquisition is running, with a lock icon shown while
  disabled. AcquisitionEngine gains a run_state_changed(bool) signal
  (emitted from start()/stop()); ControlWidget gains a
  _check_safety_lock() hook (no-op by default, called uniformly by
  ControlPanel on every widget) that SafetySwitch overrides. engine is
  now threaded through to every ControlWidget for this. Persists via
  ControlSpec.control_type alone — no schema change needed.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>

6 files changed, 87 insertions, 7 deletions

diff --git a/core/acquisition.py b/core/acquisition.py
index eeeb4c8..c900adf 100644
--- a/core/acquisition.py
+++ b/core/acquisition.py
@@ -77,6 +77,7 @@ class AcquisitionEngine(QObject):
                                    # switched lb/kgF/N/ozF on its own front panel
     log_started(filepath)
     log_stopped(filepath)
+    run_state_changed(running)   # emitted from start()/stop()
     """
 
     new_data              = pyqtSignal(float, list)
@@ -84,10 +85,14 @@ class AcquisitionEngine(QObject):
     channel_unit_changed  = pyqtSignal(str, str, str)
     log_started           = pyqtSignal(str)
     log_stopped           = pyqtSignal(str)
+    run_state_changed     = pyqtSignal(bool)   # True on start(), False on stop() —
+                                                # e.g. ControlPanel's safety-interlock
+                                                # controls listen for this
 
     def __init__(self, poll_interval_ms: int = 100):
         super().__init__()
         self._interval = poll_interval_ms / 1000.0
+        self._buffer_size: int = MAX_BUFFER   # see set_buffer_size()
         self._devices: List[BaseDevice]                    = []
         self._buffers: Dict[str, Dict[str, SignalBuffer]] = {}
         self._last_units: Dict[Tuple[str, str], str]        = {}
@@ -106,12 +111,27 @@ class AcquisitionEngine(QObject):
     def add_device(self, dev: BaseDevice):
         self._devices.append(dev)
         self._buffers[dev.info.device_id] = {
-            ch.signal_id: SignalBuffer()
+            ch.signal_id: SignalBuffer(maxlen=self._buffer_size)
             for ch in dev.info.signals
         }
         for ch in dev.info.signals:
             self._last_units[(dev.info.device_id, ch.signal_id)] = ch.unit
 
+    def set_buffer_size(self, n: int):
+        """Change how much history each Signal's buffer holds — settings_
+        window.py's "Buffer size (samples)" field, applied live rather than
+        only on the next device add/reconfigure. Rebuilds every existing
+        buffer at the new size, keeping its most recent samples (a maxlen
+        deque naturally drops the oldest first as it's extended past
+        capacity, so growing loses nothing and shrinking keeps the tail)."""
+        self._buffer_size = n
+        for dev_bufs in self._buffers.values():
+            for ch_id, buf in list(dev_bufs.items()):
+                new_buf = SignalBuffer(maxlen=n)
+                new_buf.times.extend(buf.times)
+                new_buf.values.extend(buf.values)
+                dev_bufs[ch_id] = new_buf
+
     def on_device_reconfigured(self, device_id: str):
         """Reconcile buffers with a device's current channel list — reconfigure()
         can add/remove channels (e.g. Signals count changed), and buffers keyed
@@ -125,7 +145,7 @@ class AcquisitionEngine(QObject):
             bufs.pop(stale_id, None)
         for ch in dev.info.signals:
             if ch.signal_id not in bufs:
-                bufs[ch.signal_id] = SignalBuffer()
+                bufs[ch.signal_id] = SignalBuffer(maxlen=self._buffer_size)
             self._last_units[(device_id, ch.signal_id)] = ch.unit
         for key in [k for k in self._last_units if k[0] == device_id and k[1] not in valid_ids]:
             self._last_units.pop(key, None)
@@ -176,12 +196,14 @@ class AcquisitionEngine(QObject):
         self._running = True
         self._thread  = threading.Thread(target=self._loop, daemon=True, name="DAQ-Acq")
         self._thread.start()
+        self.run_state_changed.emit(True)
 
     def stop(self):
         self._running = False
         if self._thread:
             self._thread.join(timeout=3.0)
         self.stop_logging()
+        self.run_state_changed.emit(False)
 
     # ── Logging ──────────────────────────────────────────────────────────
 
diff --git a/ui/control_editor.py b/ui/control_editor.py
index 40cde7e..e62e146 100644
--- a/ui/control_editor.py
+++ b/ui/control_editor.py
@@ -40,6 +40,7 @@ from devices.device_registry import DeviceRegistry
 
 CONTROL_TYPES = [
     "On/Off Switch",
+    "Safety Switch",
     "Motor Control",
     "PWM Output",
     "Setpoint",
@@ -48,6 +49,7 @@ CONTROL_TYPES = [
 
 CONTROL_ICONS = {
     "On/Off Switch":  "⏻",
+    "Safety Switch":  "🔒",
     "Motor Control":  "⟳",
     "PWM Output":     "⊓",
     "Setpoint":       "◎",
@@ -160,6 +162,7 @@ class AnalogOutParams(QWidget):
 
 _PARAM_PANELS = {
     "On/Off Switch":  OnOffParams,
+    "Safety Switch":  OnOffParams,   # same shape as On/Off — no extra params
     "Motor Control":  MotorParams,
     "PWM Output":     PwmParams,
     "Setpoint":       SetpointParams,
@@ -347,7 +350,7 @@ class ControlEditorDialog(QDialog):
         self._stack.setCurrentIndex(idx)
         self._stack.updateGeometry()
         self._params_grp.updateGeometry()
-        self._active_low_chk.setEnabled(type_name == "On/Off Switch")
+        self._active_low_chk.setEnabled(type_name in ("On/Off Switch", "Safety Switch"))
         # Auto-set title if still default
         if not self._title_edit.text() or \
            self._title_edit.text() in CONTROL_TYPES:
diff --git a/ui/control_panel.py b/ui/control_panel.py
index 830b985..e938ceb 100644
--- a/ui/control_panel.py
+++ b/ui/control_panel.py
@@ -126,7 +126,8 @@ class ControlWidget(QFrame):
                  registry: Optional[DeviceRegistry] = None,
                  active_low: bool = False,
                  processor=None,
-                 on_action_script: str = ""):
+                 on_action_script: str = "",
+                 engine=None):
         super().__init__()
         self.title      = title
         self.icon       = icon
@@ -135,6 +136,9 @@ class ControlWidget(QFrame):
         self.registry   = registry
         self.active_low = active_low
         self._processor = processor
+        self.engine     = engine   # AcquisitionEngine — only SafetySwitch uses this
+                                    # today (run_state_changed-driven interlock), but
+                                    # every widget gets it for future control types.
         self._on_action_fn = None
         if on_action_script.strip():
             self._compile_action(on_action_script)
@@ -142,6 +146,14 @@ class ControlWidget(QFrame):
         self._build_frame()
         self._stale = None
         self._check_stale()
+        self._check_safety_lock()
+
+    def _check_safety_lock(self):
+        """No-op for regular controls — overridden by SafetySwitch to
+        enable/disable itself based on self.engine.is_running(). Called
+        uniformly on every widget from ControlPanel._on_run_state_changed()
+        so callers never need an isinstance check."""
+        pass
 
     def _compile_action(self, script: str):
         try:
@@ -349,6 +361,37 @@ class OnOffSwitch(ControlWidget):
 
 
 # ══════════════════════════════════════════════════════════════════════════════
+#  Safety Switch — On/Off Switch, but disabled until acquisition is running
+# ══════════════════════════════════════════════════════════════════════════════
+
+class SafetySwitch(OnOffSwitch):
+    """On/Off Switch that's disabled (can't be pressed at all) until
+    acquisition is running — physical safety interlock so a critical/
+    dangerous output can't be armed before the system starts actively
+    monitoring, or left armable after it's stopped. Shows a lock icon in
+    its header while disabled. Wired to AcquisitionEngine.run_state_changed
+    via ControlPanel._on_run_state_changed(), which calls every widget's
+    _check_safety_lock() uniformly — see ControlWidget's base (no-op)
+    implementation."""
+
+    def __init__(self, title: str = "Safety", icon: str = "🔒", **kw):
+        super().__init__(title, icon=icon, **kw)
+        self._lock_lbl = QLabel("🔒")
+        self._lock_lbl.setObjectName("controlWidgetSafetyLock")
+        self._lock_lbl.setToolTip("Locked — only active while acquisition is running")
+        self._header_layout.addWidget(self._lock_lbl)
+        self._check_safety_lock()
+
+    def _check_safety_lock(self):
+        if not hasattr(self, "_lock_lbl"):
+            return   # base ControlWidget.__init__ calls this before our own
+                      # __init__ (and OnOffSwitch's _build_body()) has run
+        running = bool(self.engine and self.engine.is_running())
+        self._btn.setEnabled(running)
+        self._lock_lbl.setVisible(not running)
+
+
+# ══════════════════════════════════════════════════════════════════════════════
 #  Motor Control
 # ══════════════════════════════════════════════════════════════════════════════
 
@@ -738,11 +781,16 @@ class ControlPanel(QWidget):
         self._build()
         if engine is not None:
             engine.device_status_changed.connect(self._on_device_status_changed)
+            engine.run_state_changed.connect(self._on_run_state_changed)
 
     def _on_device_status_changed(self, device_id: str, status: str):
         for w in self._widgets:
             w._check_stale()
 
+    def _on_run_state_changed(self, running: bool):
+        for w in self._widgets:
+            w._check_safety_lock()
+
     # ── Layout ───────────────────────────────────────────────────────────────
 
     def _build(self):
@@ -793,7 +841,7 @@ class ControlPanel(QWidget):
 
     def _add_widget_from_spec(self, spec):
         """Instantiate a ControlWidget from a ControlSpec and add to panel."""
-        widget = _build_widget_from_spec(spec, self.registry, self.processor)
+        widget = _build_widget_from_spec(spec, self.registry, self.processor, self.engine)
         if widget is None:
             return
         self._wire_widget(widget, spec)
@@ -897,7 +945,7 @@ class ControlPanel(QWidget):
         self._widgets.pop(idx); self._specs.pop(idx)
 
         # Insert new one at same position
-        new_widget = _build_widget_from_spec(new_spec, self.registry, self.processor)
+        new_widget = _build_widget_from_spec(new_spec, self.registry, self.processor, self.engine)
         if new_widget is None:
             return
         self._wire_widget(new_widget, new_spec)
@@ -931,7 +979,7 @@ class ControlPanel(QWidget):
 # ── Factory — build a ControlWidget from a ControlSpec ─────────────────────────
 
 def _build_widget_from_spec(spec, registry: DeviceRegistry,
-                            processor=None) -> Optional[ControlWidget]:
+                            processor=None, engine=None) -> Optional[ControlWidget]:
     """Instantiate the right ControlWidget subclass from a ControlSpec."""
     # Base kwargs — icon is NOT included here; it's passed explicitly below
     # so subclasses never get a double-value collision.
@@ -942,12 +990,15 @@ def _build_widget_from_spec(spec, registry: DeviceRegistry,
         active_low=getattr(spec, "active_low", False),
         processor=processor,
         on_action_script=getattr(spec, "on_action_script", ""),
+        engine=engine,
     )
     t   = spec.control_type
     ttl = spec.title
     ico = spec.icon
     if t == "On/Off Switch":
         return OnOffSwitch(title=ttl, icon=ico, **base_kw)
+    elif t == "Safety Switch":
+        return SafetySwitch(title=ttl, icon=ico, **base_kw)
     elif t == "Motor Control":
         return MotorControl(title=ttl, icon=ico, max_rpm=spec.max_rpm, **base_kw)
     elif t == "PWM Output":
diff --git a/ui/main_window.py b/ui/main_window.py
index 6dae1be..07ab0b2 100644
--- a/ui/main_window.py
+++ b/ui/main_window.py
@@ -827,6 +827,7 @@ class MainWindow(QMainWindow):
     def _apply_settings_on_startup(self):
         self._apply_theme(self._settings.get("theme", "dark"))
         self.engine._interval = self._settings.get("poll_ms", 100) / 1000.0
+        self.engine.set_buffer_size(self._settings.get("buffer_size", 20000))
         self._apply_developer_mode(self._settings.get("developer_mode", False))
         QTimer.singleShot(0, self._apply_dock_state)
 
@@ -862,6 +863,7 @@ class MainWindow(QMainWindow):
     def _on_settings(self, cfg: dict):
         self._settings.update(cfg)
         self.engine._interval = cfg.get("poll_ms", 100) / 1000.0
+        self.engine.set_buffer_size(cfg.get("buffer_size", 20000))
         self._apply_developer_mode(cfg.get("developer_mode", False))
         save_settings(self._settings)
 
diff --git a/ui/style_dark.qss b/ui/style_dark.qss
index 08b82e9..3a20cba 100644
--- a/ui/style_dark.qss
+++ b/ui/style_dark.qss
@@ -420,6 +420,7 @@ QWidget#controlWidgetHeader { background-color: #0f1521; border-radius: 5px 5px
 QLabel#controlWidgetIcon  { font-size: 14px; color: #3b82f6; padding-right: 4px; }
 QLabel#controlWidgetTitle { font-family: "IBM Plex Mono", monospace; font-size: 11px; font-weight: 700; letter-spacing: 1.5px; color: #8b9dc3; }
 QLabel#controlWidgetStale { color: #f59e0b; font-size: 12px; padding: 0 2px; }
+QLabel#controlWidgetSafetyLock { color: #64748b; font-size: 12px; padding: 0 2px; }
 QWidget#controlWidgetBody { background-color: #161d2e; border-radius: 0 0 5px 5px; }
 QFrame#controlWidget[stale="true"] QWidget#controlWidgetBody { background-color: #1c1710; }
 
diff --git a/ui/style_light.qss b/ui/style_light.qss
index b9c8b62..1bed344 100644
--- a/ui/style_light.qss
+++ b/ui/style_light.qss
@@ -83,6 +83,7 @@ QWidget#controlWidgetHeader { background:#f1f5f9; border-radius:5px 5px 0 0; bor
 QLabel#controlWidgetIcon  { font-size:14px; color:#3b82f6; padding-right:4px; }
 QLabel#controlWidgetTitle { font-family:"IBM Plex Mono",monospace; font-size:11px; font-weight:700; letter-spacing:1.5px; color:#64748b; }
 QLabel#controlWidgetStale { color:#d97706; font-size:12px; padding:0 2px; }
+QLabel#controlWidgetSafetyLock { color:#64748b; font-size:12px; padding:0 2px; }
 QWidget#controlWidgetBody { background:#ffffff; border-radius:0 0 5px 5px; }
 QFrame#controlWidget[stale="true"] QWidget#controlWidgetBody { background:#fffbeb; }