fix(export): stream large bucket exports without JSON.parse

[TimeToBuildBob]

Problem

Large all-bucket exports (500k+ events) silently no-op on Android and desktop.

Two stacked root causes:

1. Server buffers before responding — aw-server-rust serializes all events to a temp file before sending the first HTTP byte (even after perf(export): serialize HTTP exports with bounded event buffering aw-server-rust#677). For 500k events on a phone, serialization can take 30+ seconds, which silently exceeds axios's default timeout. No error is shown to the user.

2. JS double-serialization — JSON.stringify(response.data, null, 2) re-parses and re-stringifies an already-valid JSON response in the browser heap, doubling peak memory use for large exports.

Reported and confirmed on 0.14.2b4: ActivityWatch/aw-android#228

Fix

Keep the authenticated axios client, skip JSON parse/pretty-print:

• responseType: 'blob' + timeout: 300_000 (5-minute cap, not the 30s default, no JS object graph)
• Spinner + disable the all-buckets button while any export is in flight (export_inflight counter)
• User-visible error alert on failure instead of a silent drop
• Android WebView: hand the URL to Android.exportFromUrl when the native bridge is present

Follow-up 3f26892 keeps Authorization: Bearer (Greptile P1) and counts in-flight exports (P2). 2005bb6 restores a finite 5-minute timeout so a stalled export cannot leave the spinner stuck. The original fetch() path is gone.

What this doesn't fix

The server-side streaming issue (stream headers before full serialization) is still needed for very large datasets and very slow phones. ActivityWatch/aw-server-rust#721 covers that. This PR raises the practical timeout cap and makes failures visible until that lands.

Testing

• Small export: works as before
• Large export: no longer a silent no-op; shows spinner; shows error if still too slow
• Error state: dismissible alert appears; button re-enables after failure or timeout

[codecov]

Codecov Report

❌ Patch coverage is 53.84615% with 6 lines in your changes missing coverage. Please review.
✅ Project coverage is 57.66%. Comparing base (22cb53b) to head (2005bb6).

Files with missing lines	Patch %	Lines
src/util/export.ts	53.84%	5 Missing and 1 partial ⚠️

Additional details and impacted files

@@            Coverage Diff             @@
##           master     #993      +/-   ##
==========================================
+ Coverage   57.62%   57.66%   +0.03%     
==========================================
  Files          51       51              
  Lines        3219     3231      +12     
  Branches      751      794      +43     
==========================================
+ Hits         1855     1863       +8     
+ Misses       1348     1291      -57     
- Partials       16       77      +61     

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[greptile-apps]

Confidence Score: 5/5

The PR appears safe to merge; the finite timeout resolves the remaining stalled-export state without regressing authentication or concurrent export tracking.

Summary

This PR changes bucket JSON exports to avoid parsing and re-serializing large responses in JavaScript.

• Uses the authenticated Axios client with blob responses and a finite five-minute timeout.
• Delegates Android exports to the native URL bridge when available.
• Tracks overlapping exports and presents progress and failure states.
• Adds coverage for the Android bridge and export request configuration.

Diagram

%%{init: {'theme': 'neutral'}}%%
flowchart TD
  A[User starts JSON export] --> B{Android export bridge available?}
  B -->|Yes| C[Delegate URL and filename to native bridge]
  B -->|No| D[Increment in-flight counter]
  D --> E[Authenticated Axios request]
  E --> F[Blob response with five-minute timeout]
  F --> G[Save blob without JSON parsing]
  E -->|Failure or timeout| H[Show dismissible export error]
  G --> I[Decrement in-flight counter]
  H --> I

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_{Reviews (3) · Last reviewed commit: "fix(export): use a 5-minute axios timeou..."}

[TimeToBuildBob]

CI-green and mergeable — waiting only on a maintainer click.

This PR is ready to merge, but the bot has pull-only access to this repo and can't self-merge — surfacing it here so it isn't lost. The monitoring loop will stop re-flagging it now that this note is posted.

[TimeToBuildBob]

@greptileai review

[TimeToBuildBob]

@greptileai review