Fix Android app OOM crash on 4K images and crash loop recovery

A 4K image assigned to a 1080p display decoded as a ~33 MB ARGB_8888
bitmap and OOM'd. Worse, the cached playlist on disk meant relaunch
hit the same image and crashed again — only a reinstall recovered.

New ImageLoader utility reads bounds via inJustDecodeBounds, computes
inSampleSize against the device screen (or zone size for multi-zone
layouts), and returns null on OOM/Throwable so callers skip the item
instead of crashing. MediaPlayerManager exposes an onImageError
callback wired to playlistController.next() so a bad item advances
the playlist. The cached-playlist restore in onCreate now catches
Throwable (was Exception) and clears the cache on any failure,
breaking the crash loop. android:largeHeap="true" added as belt and
braces.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

android/app/src/main/AndroidManifest.xml

@@ -20,6 +20,7 @@
         android:allowBackup="true"
         android:icon="@android:drawable/ic_media_play"
         android:label="RemoteDisplay"
+        android:largeHeap="true"
         android:theme="@style/Theme.RemoteDisplay"
         android:usesCleartextTraffic="true"
         android:supportsRtl="true">

android/app/src/main/java/com/remotedisplay/player/MainActivity.kt

@@ -144,10 +144,17 @@ class MainActivity : AppCompatActivity() {
             playerView = playerView,
             imageView = imageView,
             youtubeWebView = youtubeWebView,
-            onVideoComplete = { playlistController.onVideoComplete() }
+            onVideoComplete = { playlistController.onVideoComplete() },
+            onImageError = {
+                Log.w("MainActivity", "Image failed to load, skipping to next item")
+                handler.postDelayed({ playlistController.next() }, 500)
+            }
         )
 
-        // Restore cached playlist for offline cold-start (play immediately from disk cache)
+        // Restore cached playlist for offline cold-start (play immediately from disk cache).
+        // Catch Throwable (not just Exception) so an OOM or corrupt entry can't kill the app
+        // before the WebSocket connects — that's the crash-loop scenario. If the cache is
+        // unusable for any reason, drop it and continue; the server will resend on connect.
         val cachedJson = config.cachedPlaylist
         if (cachedJson.isNotEmpty()) {
             try {
@@ -158,8 +165,9 @@ class MainActivity : AppCompatActivity() {
                     playlistController.updatePlaylist(assignments)
                     playlistController.startIfNeeded()
                 }
-            } catch (e: Exception) {
-                Log.w("MainActivity", "Failed to restore cached playlist: ${e.message}")
+            } catch (e: Throwable) {
+                Log.w("MainActivity", "Failed to restore cached playlist, clearing cache: ${e.message}")
+                try { config.clearPlaylistCache() } catch (_: Throwable) {}
             }
         }
 

android/app/src/main/java/com/remotedisplay/player/player/MediaPlayerManager.kt

@@ -11,6 +11,7 @@ import androidx.media3.common.MediaItem
 import androidx.media3.common.Player
 import androidx.media3.exoplayer.ExoPlayer
 import androidx.media3.ui.PlayerView
+import com.remotedisplay.player.util.ImageLoader
 import java.io.File
 
 class MediaPlayerManager(
@@ -18,7 +19,8 @@ class MediaPlayerManager(
     private val playerView: PlayerView,
     private val imageView: ImageView,
     private val youtubeWebView: WebView? = null,
-    private val onVideoComplete: () -> Unit
+    private val onVideoComplete: () -> Unit,
+    private val onImageError: (() -> Unit)? = null
 ) {
     private var exoPlayer: ExoPlayer? = null
     private var currentType: MediaType = MediaType.NONE
@@ -89,20 +91,16 @@ class MediaPlayerManager(
 
         exoPlayer?.stop()
 
-        // Load image from URL in background
         Thread {
-            try {
-                val connection = java.net.URL(url).openConnection()
-                connection.connectTimeout = 10000
-                connection.readTimeout = 30000
-                val input = connection.getInputStream()
-                val bitmap = android.graphics.BitmapFactory.decodeStream(input)
-                input.close()
+            val bitmap = ImageLoader.decodeUrl(url, ImageLoader.screenWidth(context), ImageLoader.screenHeight(context))
             if (bitmap != null) {
-                    imageView.post { imageView.setImageBitmap(bitmap) }
+                imageView.post {
+                    try { imageView.setImageBitmap(bitmap) }
+                    catch (e: Throwable) { Log.e("MediaPlayerManager", "setImageBitmap failed: ${e.message}"); onImageError?.invoke() }
                 }
-            } catch (e: Exception) {
-                Log.e("MediaPlayerManager", "Remote image load failed: ${e.message}")
+            } else {
+                Log.w("MediaPlayerManager", "Skipping unloadable remote image: $url")
+                imageView.post { onImageError?.invoke() }
             }
         }.start()
     }
@@ -128,24 +126,23 @@ class MediaPlayerManager(
         Log.i("MediaPlayerManager", "Showing image: ${file.absolutePath}")
         currentType = MediaType.IMAGE
 
-        // Show image, hide player
         playerView.visibility = android.view.View.GONE
         imageView.visibility = android.view.View.VISIBLE
         youtubeWebView?.visibility = android.view.View.GONE
 
-        // Stop video if playing
         exoPlayer?.stop()
 
-        // Load image
-        try {
-            val bitmap = android.graphics.BitmapFactory.decodeFile(file.absolutePath)
-            if (bitmap != null) {
-                imageView.setImageBitmap(bitmap)
-            } else {
-                Log.e("MediaPlayerManager", "Failed to decode image: ${file.absolutePath}")
+        val bitmap = ImageLoader.decodeFile(file, ImageLoader.screenWidth(context), ImageLoader.screenHeight(context))
+        if (bitmap == null) {
+            Log.w("MediaPlayerManager", "Skipping unloadable image: ${file.name}")
+            onImageError?.invoke()
+            return
         }
-        } catch (e: Exception) {
-            Log.e("MediaPlayerManager", "Error loading image: ${e.message}")
+        try {
+            imageView.setImageBitmap(bitmap)
+        } catch (e: Throwable) {
+            Log.e("MediaPlayerManager", "setImageBitmap failed: ${e.message}")
+            onImageError?.invoke()
         }
     }
 

android/app/src/main/java/com/remotedisplay/player/player/ZoneManager.kt

@@ -180,22 +180,30 @@ class ZoneManager(
                         layoutParams = params
                     }
 
-                    // Load image
+                    // Target the zone size (already known) so we don't decode larger than the
+                    // visible region. Falls back to screen size if zone hasn't been measured.
+                    val targetW = if (w > 0) w else com.remotedisplay.player.util.ImageLoader.screenWidth(context)
+                    val targetH = if (h > 0) h else com.remotedisplay.player.util.ImageLoader.screenHeight(context)
+
                     val file = contentId?.let { contentCache.getCachedFile(it) }
                     if (file != null) {
-                        val bitmap = android.graphics.BitmapFactory.decodeFile(file.absolutePath)
-                        if (bitmap != null) imageView.setImageBitmap(bitmap)
+                        val bitmap = com.remotedisplay.player.util.ImageLoader.decodeFile(file, targetW, targetH)
+                        if (bitmap != null) {
+                            try { imageView.setImageBitmap(bitmap) }
+                            catch (e: Throwable) { Log.e(TAG, "setImageBitmap failed: ${e.message}") }
+                        } else {
+                            Log.w(TAG, "Zone ${zone.name}: skipping unloadable image $contentId")
+                        }
                     } else if (!remoteUrl.isNullOrEmpty()) {
-                        // Load from URL in background
                         Thread {
-                            try {
-                                val connection = java.net.URL(remoteUrl).openConnection()
-                                val input = connection.getInputStream()
-                                val bitmap = android.graphics.BitmapFactory.decodeStream(input)
-                                input.close()
-                                imageView.post { if (bitmap != null) imageView.setImageBitmap(bitmap) }
-                            } catch (e: Exception) {
-                                Log.e(TAG, "Image load failed: ${e.message}")
+                            val bitmap = com.remotedisplay.player.util.ImageLoader.decodeUrl(remoteUrl, targetW, targetH)
+                            if (bitmap != null) {
+                                imageView.post {
+                                    try { imageView.setImageBitmap(bitmap) }
+                                    catch (e: Throwable) { Log.e(TAG, "setImageBitmap failed: ${e.message}") }
+                                }
+                            } else {
+                                Log.w(TAG, "Zone ${zone.name}: skipping unloadable remote image")
                             }
                         }.start()
                     }

android/app/src/main/java/com/remotedisplay/player/util/ImageLoader.kt

@@ -0,0 +1,86 @@
+package com.remotedisplay.player.util
+
+import android.content.Context
+import android.graphics.Bitmap
+import android.graphics.BitmapFactory
+import android.util.Log
+import java.io.File
+import java.net.URL
+
+/**
+ * Safe bitmap loader. Reads dimensions first via inJustDecodeBounds, then decodes
+ * with an inSampleSize that scales the image down to the device's screen resolution.
+ * A 4K source image on a 1080p screen ends up as 1920x1080, not 3840x2160 — keeps
+ * the bitmap under ~8 MB instead of ~33 MB.
+ *
+ * All exceptions, including OutOfMemoryError, return null so the caller can skip the
+ * item rather than crashing the whole app.
+ */
+object ImageLoader {
+    private const val TAG = "ImageLoader"
+
+    fun screenWidth(ctx: Context): Int = ctx.resources.displayMetrics.widthPixels
+    fun screenHeight(ctx: Context): Int = ctx.resources.displayMetrics.heightPixels
+
+    fun decodeFile(file: File, maxW: Int, maxH: Int): Bitmap? {
+        return try {
+            val bounds = BitmapFactory.Options().apply { inJustDecodeBounds = true }
+            BitmapFactory.decodeFile(file.absolutePath, bounds)
+            if (bounds.outWidth <= 0 || bounds.outHeight <= 0) {
+                Log.w(TAG, "Invalid image dimensions for ${file.name}")
+                return null
+            }
+            val opts = BitmapFactory.Options().apply {
+                inSampleSize = calcSampleSize(bounds.outWidth, bounds.outHeight, maxW, maxH)
+            }
+            BitmapFactory.decodeFile(file.absolutePath, opts)
+        } catch (e: OutOfMemoryError) {
+            Log.e(TAG, "OOM decoding ${file.name}: ${e.message}")
+            null
+        } catch (e: Throwable) {
+            Log.e(TAG, "Failed to decode ${file.name}: ${e.message}")
+            null
+        }
+    }
+
+    fun decodeUrl(url: String, maxW: Int, maxH: Int): Bitmap? {
+        return try {
+            val bytes = URL(url).openConnection().apply {
+                connectTimeout = 10_000
+                readTimeout = 30_000
+            }.getInputStream().use { it.readBytes() }
+            decodeBytes(bytes, maxW, maxH)
+        } catch (e: OutOfMemoryError) {
+            Log.e(TAG, "OOM downloading $url: ${e.message}")
+            null
+        } catch (e: Throwable) {
+            Log.e(TAG, "Failed to download $url: ${e.message}")
+            null
+        }
+    }
+
+    private fun decodeBytes(bytes: ByteArray, maxW: Int, maxH: Int): Bitmap? {
+        return try {
+            val bounds = BitmapFactory.Options().apply { inJustDecodeBounds = true }
+            BitmapFactory.decodeByteArray(bytes, 0, bytes.size, bounds)
+            if (bounds.outWidth <= 0 || bounds.outHeight <= 0) return null
+            val opts = BitmapFactory.Options().apply {
+                inSampleSize = calcSampleSize(bounds.outWidth, bounds.outHeight, maxW, maxH)
+            }
+            BitmapFactory.decodeByteArray(bytes, 0, bytes.size, opts)
+        } catch (e: OutOfMemoryError) {
+            Log.e(TAG, "OOM decoding ${bytes.size} bytes: ${e.message}")
+            null
+        } catch (e: Throwable) {
+            Log.e(TAG, "Failed to decode ${bytes.size} bytes: ${e.message}")
+            null
+        }
+    }
+
+    private fun calcSampleSize(srcW: Int, srcH: Int, maxW: Int, maxH: Int): Int {
+        if (maxW <= 0 || maxH <= 0) return 1
+        var sample = 1
+        while (srcW / sample > maxW || srcH / sample > maxH) sample *= 2
+        return sample
+    }
+}