fix: restore per-rep breaks with audio/vibration

Breaks belong after each rep (circle tap), not removed entirely.
Restored break_banner, audioplayers, vibration, and break_end.mp3 asset.
Break triggers on every circle tap except the last one; 3 min on success,
5 min on failure; sound + vibration fires when the countdown ends.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

stronglift_replacement/workout_app/lib/screens/workout_screen.dart

@@ -1,18 +1,25 @@
-/// Active workout screen: warmup, back-button protection,
+/// Active workout screen: per-rep breaks, warmup, back-button protection,
 /// and crash-safe session persistence.
 library;
 
 import 'dart:async';
 import 'package:flutter/material.dart';
+import 'package:audioplayers/audioplayers.dart';
+import 'package:vibration/vibration.dart';
 import 'package:workout_app/models/exercise.dart';
 import 'package:workout_app/models/exercise_result.dart';
 import 'package:workout_app/models/set_result.dart';
 import 'package:workout_app/models/workout_session.dart';
 import 'package:workout_app/services/storage_service.dart';
 import 'package:workout_app/services/sync_service.dart';
+import 'package:workout_app/widgets/break_banner.dart';
 import 'package:workout_app/widgets/exercise_tile.dart';
 import 'package:workout_app/widgets/workout_summary_dialog.dart';
 
+const _successBreakSecs = 180; // 3 min after successful rep
+const _failBreakSecs = 300; // 5 min after failed rep
+const _warmupBreakSecs = 180; // 3 min after warmup
+
 class WorkoutScreen extends StatefulWidget {
   const WorkoutScreen({
     super.key,
@@ -39,6 +46,18 @@ class _WorkoutScreenState extends State<WorkoutScreen> {
   late Timer _elapsedTimer;
   Duration _elapsed = Duration.zero;
 
+  // Break state
+  int _breakRemaining = 0;
+  int _breakDurationSecs = 0;
+  DateTime? _breakStartTime;
+  Timer? _breakTimer;
+  String _breakLabel = '';
+  int _breakForExIdx = -1;
+  int _breakForRepIdx = -1; // -1 = warmup break
+
+  bool get _inBreak => _breakRemaining > 0;
+
+  final _audio = AudioPlayer();
   final _sync = SyncService();
   bool _finished = false;
 
@@ -78,11 +97,29 @@ class _WorkoutScreenState extends State<WorkoutScreen> {
         .map((row) => (row as List).cast<int>())
         .toList();
     _warmupTapped = (s['warmupTapped'] as List).cast<bool>();
+
+    final breakEndMs = s['breakEndMs'] as int? ?? 0;
+    final breakDur = s['breakDurationSecs'] as int? ?? 0;
+    if (breakEndMs > 0 && breakDur > 0) {
+      final endTime = DateTime.fromMillisecondsSinceEpoch(breakEndMs);
+      final remaining = endTime.difference(DateTime.now()).inSeconds;
+      if (remaining > 0) {
+        _breakForExIdx = s['breakForExIdx'] as int? ?? -1;
+        _breakForRepIdx = s['breakForRepIdx'] as int? ?? -1;
+        _breakLabel = s['breakLabel'] as String? ?? 'Rest';
+        _breakDurationSecs = breakDur;
+        _breakStartTime = endTime.subtract(Duration(seconds: breakDur));
+        _breakRemaining = remaining;
+        _breakTimer = Timer.periodic(const Duration(seconds: 1), _tickBreak);
+      }
+    }
   }
 
   @override
   void dispose() {
     _elapsedTimer.cancel();
+    _breakTimer?.cancel();
+    _audio.dispose();
     super.dispose();
   }
 
@@ -95,6 +132,15 @@ class _WorkoutScreenState extends State<WorkoutScreen> {
       'tapped': _tapped,
       'doneReps': _doneReps,
       'warmupTapped': _warmupTapped,
+      'breakForExIdx': _breakForExIdx,
+      'breakForRepIdx': _breakForRepIdx,
+      'breakLabel': _breakLabel,
+      'breakDurationSecs': _breakDurationSecs,
+      'breakEndMs': _breakStartTime != null
+          ? _breakStartTime!
+              .add(Duration(seconds: _breakDurationSecs))
+              .millisecondsSinceEpoch
+          : 0,
     });
   }
 
@@ -108,33 +154,142 @@ class _WorkoutScreenState extends State<WorkoutScreen> {
 
   bool get _allSetsCompleted => _tapped.every((row) => row.every((t) => t));
 
+  bool _isLastUntappedCircle(int exIdx, int repIdx) {
+    int remaining = 0;
+    for (int i = 0; i < widget.exercises.length; i++) {
+      for (int s = 0; s < widget.exercises[i].sets; s++) {
+        if (!_tapped[i][s]) remaining++;
+      }
+    }
+    return remaining == 1;
+  }
+
   // ── Interaction ────────────────────────────────────────────────────────────
 
-  void _tapCircle(int exIdx, int setIdx) {
+  void _tapCircle(int exIdx, int repIdx) {
     if (_finished) return;
+
+    final wasNotTapped = !_tapped[exIdx][repIdx];
+    if (wasNotTapped && _inBreak) return;
+
     setState(() {
-      if (!_tapped[exIdx][setIdx]) {
-        _tapped[exIdx][setIdx] = true;
+      if (wasNotTapped) {
+        _tapped[exIdx][repIdx] = true;
       } else {
         // Subsequent taps decrement reps (records actual reps done).
-        _doneReps[exIdx][setIdx] =
-            (_doneReps[exIdx][setIdx] - 1).clamp(0, 999);
+        _doneReps[exIdx][repIdx] =
+            (_doneReps[exIdx][repIdx] - 1).clamp(0, 999);
+        _recomputeBreakIfNeeded(exIdx, repIdx);
       }
     });
+
+    if (wasNotTapped) {
+      final isLast = _isLastUntappedCircle(exIdx, repIdx);
+      if (!isLast) {
+        final succeeded =
+            _doneReps[exIdx][repIdx] >= widget.exercises[exIdx].reps;
+        _startBreak(
+          succeeded ? _successBreakSecs : _failBreakSecs,
+          succeeded
+              ? 'Rest (3 min — well done!)'
+              : 'Rest (5 min — keep going!)',
+          exIdx,
+          repIdx,
+        );
+      }
+    }
+
     _saveActiveSession();
   }
 
   void _tapWarmup(int exIdx) {
     if (_finished || _warmupTapped[exIdx]) return;
     setState(() => _warmupTapped[exIdx] = true);
+    if (!_inBreak) {
+      _startBreak(_warmupBreakSecs, 'Warmup rest (3 min)', exIdx, -1);
+    }
     _saveActiveSession();
   }
 
-  void _resetCircle(int exIdx, int setIdx) {
+  void _resetCircle(int exIdx, int repIdx) {
     if (_finished) return;
     setState(() {
-      _tapped[exIdx][setIdx] = false;
-      _doneReps[exIdx][setIdx] = widget.exercises[exIdx].reps;
+      _tapped[exIdx][repIdx] = false;
+      _doneReps[exIdx][repIdx] = widget.exercises[exIdx].reps;
+    });
+    if (_breakForExIdx == exIdx && _breakForRepIdx == repIdx) {
+      _cancelBreak();
+    }
+    _saveActiveSession();
+  }
+
+  // ── Break management ───────────────────────────────────────────────────────
+
+  void _startBreak(int secs, String label, int exIdx, int repIdx) {
+    _breakTimer?.cancel();
+    setState(() {
+      _breakDurationSecs = secs;
+      _breakRemaining = secs;
+      _breakLabel = label;
+      _breakForExIdx = exIdx;
+      _breakForRepIdx = repIdx;
+      _breakStartTime = DateTime.now();
+    });
+    _breakTimer = Timer.periodic(const Duration(seconds: 1), _tickBreak);
+  }
+
+  void _tickBreak(Timer t) {
+    setState(() => _breakRemaining--);
+    if (_breakRemaining <= 0) {
+      t.cancel();
+      _onBreakFinished();
+    }
+  }
+
+  void _cancelBreak() {
+    _breakTimer?.cancel();
+    setState(() {
+      _breakRemaining = 0;
+      _breakForExIdx = -1;
+      _breakForRepIdx = -1;
+      _breakStartTime = null;
+    });
+  }
+
+  void _skipBreak() {
+    _cancelBreak();
+    _saveActiveSession();
+  }
+
+  /// If the user reduces reps on the rep that triggered the current break,
+  /// switch from 3-min to 5-min (or vice versa).
+  void _recomputeBreakIfNeeded(int exIdx, int repIdx) {
+    if (!_inBreak) return;
+    if (_breakForExIdx != exIdx || _breakForRepIdx != repIdx) return;
+    if (_breakForRepIdx == -1) return; // warmup break, never recompute
+
+    final succeeded =
+        _doneReps[exIdx][repIdx] >= widget.exercises[exIdx].reps;
+    final newDuration = succeeded ? _successBreakSecs : _failBreakSecs;
+    if (newDuration == _breakDurationSecs) return;
+
+    final elapsed = DateTime.now().difference(_breakStartTime!).inSeconds;
+    final newRemaining = (newDuration - elapsed).clamp(0, newDuration);
+
+    _breakDurationSecs = newDuration;
+    _breakRemaining = newRemaining;
+    _breakLabel =
+        succeeded ? 'Rest (3 min — well done!)' : 'Rest (5 min — keep going!)';
+  }
+
+  Future<void> _onBreakFinished() async {
+    await _audio.play(AssetSource('sounds/break_end.mp3')).catchError((_) {});
+    final hasVibrator = await Vibration.hasVibrator() == true;
+    if (hasVibrator) Vibration.vibrate(duration: 800);
+    setState(() {
+      _breakForExIdx = -1;
+      _breakForRepIdx = -1;
+      _breakStartTime = null;
     });
     _saveActiveSession();
   }
@@ -153,12 +308,15 @@ class _WorkoutScreenState extends State<WorkoutScreen> {
         actions: [
           TextButton(
             onPressed: () => Navigator.pop(context, false),
-            child: const Text('Cancel', style: TextStyle(color: Colors.white70)),
+            child:
+                const Text('Cancel', style: TextStyle(color: Colors.white70)),
           ),
           TextButton(
             onPressed: () => Navigator.pop(context, true),
-            child:
-                const Text('Finish', style: TextStyle(color: Colors.greenAccent)),
+            child: const Text(
+              'Finish',
+              style: TextStyle(color: Colors.greenAccent),
+            ),
           ),
         ],
       ),
@@ -201,6 +359,7 @@ class _WorkoutScreenState extends State<WorkoutScreen> {
 
   Future<void> _finishWorkout() async {
     _elapsedTimer.cancel();
+    _breakTimer?.cancel();
     setState(() => _finished = true);
 
     final endTime = DateTime.now();
@@ -301,19 +460,31 @@ class _WorkoutScreenState extends State<WorkoutScreen> {
               ),
           ],
         ),
-        body: ListView.separated(
-          padding: const EdgeInsets.all(12),
-          itemCount: widget.exercises.length,
-          separatorBuilder: (_, _) => const SizedBox(height: 8),
-          itemBuilder: (_, i) => ExerciseTile(
-            exercise: widget.exercises[i],
-            tapped: _tapped[i],
-            doneReps: _doneReps[i],
-            warmupTapped: _warmupTapped[i],
-            onTapCircle: (s) => _tapCircle(i, s),
-            onLongPressCircle: (s) => _resetCircle(i, s),
-            onTapWarmup: () => _tapWarmup(i),
-          ),
+        body: Column(
+          children: [
+            if (_inBreak)
+              BreakBanner(
+                breakRemaining: _breakRemaining,
+                breakLabel: _breakLabel,
+                onSkip: _skipBreak,
+              ),
+            Expanded(
+              child: ListView.separated(
+                padding: const EdgeInsets.all(12),
+                itemCount: widget.exercises.length,
+                separatorBuilder: (_, _) => const SizedBox(height: 8),
+                itemBuilder: (_, i) => ExerciseTile(
+                  exercise: widget.exercises[i],
+                  tapped: _tapped[i],
+                  doneReps: _doneReps[i],
+                  warmupTapped: _warmupTapped[i],
+                  onTapCircle: (s) => _tapCircle(i, s),
+                  onLongPressCircle: (s) => _resetCircle(i, s),
+                  onTapWarmup: () => _tapWarmup(i),
+                ),
+              ),
+            ),
+          ],
         ),
       ),
     );

stronglift_replacement/workout_app/lib/widgets/break_banner.dart

@@ -0,0 +1,63 @@
+/// Countdown banner displayed at the top of the workout screen during a rest.
+library;
+
+import 'package:flutter/material.dart';
+
+class BreakBanner extends StatelessWidget {
+  const BreakBanner({
+    super.key,
+    required this.breakRemaining,
+    required this.breakLabel,
+    required this.onSkip,
+  });
+
+  final int breakRemaining;
+  final String breakLabel;
+  final VoidCallback onSkip;
+
+  String _fmt(int secs) {
+    final m = (secs ~/ 60).toString().padLeft(2, '0');
+    final s = (secs % 60).toString().padLeft(2, '0');
+    return '$m:$s';
+  }
+
+  @override
+  Widget build(BuildContext context) {
+    return Container(
+      color: Colors.indigo.shade900,
+      padding: const EdgeInsets.symmetric(horizontal: 16, vertical: 10),
+      child: Row(
+        children: [
+          Expanded(
+            child: Column(
+              crossAxisAlignment: CrossAxisAlignment.start,
+              mainAxisSize: MainAxisSize.min,
+              children: [
+                Text(
+                  breakLabel,
+                  style: const TextStyle(color: Colors.white70, fontSize: 12),
+                ),
+                Text(
+                  _fmt(breakRemaining),
+                  style: const TextStyle(
+                    color: Colors.white,
+                    fontSize: 26,
+                    fontWeight: FontWeight.bold,
+                    fontFeatures: [FontFeature.tabularFigures()],
+                  ),
+                ),
+              ],
+            ),
+          ),
+          TextButton(
+            onPressed: onSkip,
+            child: const Text(
+              'Skip',
+              style: TextStyle(color: Colors.white70),
+            ),
+          ),
+        ],
+      ),
+    );
+  }
+}

stronglift_replacement/workout_app/pubspec.lock

@@ -17,6 +17,62 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "2.13.1"
+  audioplayers:
+    dependency: "direct main"
+    description:
+      name: audioplayers
+      sha256: "1d0c1b1f2095e59080e2d5046639096417a86687d89778da41b0c9a06d683dfd"
+      url: "https://pub.dev"
+    source: hosted
+    version: "6.7.0"
+  audioplayers_android:
+    dependency: transitive
+    description:
+      name: audioplayers_android
+      sha256: "60a6728277228413a85755bd3ffd6fab98f6555608923813ce383b190a360605"
+      url: "https://pub.dev"
+    source: hosted
+    version: "5.2.1"
+  audioplayers_darwin:
+    dependency: transitive
+    description:
+      name: audioplayers_darwin
+      sha256: c994b3bb3a921e4904ac40e013fbc94488e824fd7c1de6326f549943b0b44a91
+      url: "https://pub.dev"
+    source: hosted
+    version: "6.4.0"
+  audioplayers_linux:
+    dependency: transitive
+    description:
+      name: audioplayers_linux
+      sha256: f75bce1ce864170ef5e6a2c6a61cd3339e1a17ce11e99a25bae4474ea491d001
+      url: "https://pub.dev"
+    source: hosted
+    version: "4.2.1"
+  audioplayers_platform_interface:
+    dependency: transitive
+    description:
+      name: audioplayers_platform_interface
+      sha256: "0e2f6a919ab56d0fec272e801abc07b26ae7f31980f912f24af4748763e5a656"
+      url: "https://pub.dev"
+    source: hosted
+    version: "7.1.1"
+  audioplayers_web:
+    dependency: transitive
+    description:
+      name: audioplayers_web
+      sha256: "24a6f258062bd7da8cb2157e83fccb9816a08dd306cbaaa24f9813d071470545"
+      url: "https://pub.dev"
+    source: hosted
+    version: "5.2.1"
+  audioplayers_windows:
+    dependency: transitive
+    description:
+      name: audioplayers_windows
+      sha256: "95f875a96c88c3dbbcb608d4f8288e300b0113d256a81d0b3197fcc18f0dc91a"
+      url: "https://pub.dev"
+    source: hosted
+    version: "4.3.1"
   boolean_selector:
     dependency: transitive
     description:
@@ -65,6 +121,22 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "3.0.7"
+  device_info_plus:
+    dependency: transitive
+    description:
+      name: device_info_plus
+      sha256: "6a642e1daa10190af89ba6cb6386c0df7d071a3592080bfe1e44faa63ae1df65"
+      url: "https://pub.dev"
+    source: hosted
+    version: "13.1.0"
+  device_info_plus_platform_interface:
+    dependency: transitive
+    description:
+      name: device_info_plus_platform_interface
+      sha256: "04b173a92e2d9161dfead145667037c8d834db725ce2e7b942bfe18fd2f45a46"
+      url: "https://pub.dev"
+    source: hosted
+    version: "8.1.0"
   fake_async:
     dependency: transitive
     description:
@@ -81,6 +153,14 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "2.2.0"
+  ffi_leak_tracker:
+    dependency: transitive
+    description:
+      name: ffi_leak_tracker
+      sha256: "4093d4ef9ca06ffe2786e73bfb25e22aa92112b9bb4ec941f11e3e6b61489a97"
+      url: "https://pub.dev"
+    source: hosted
+    version: "0.1.2"
   file:
     dependency: transitive
     description:
@@ -89,6 +169,14 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "7.0.1"
+  fixnum:
+    dependency: transitive
+    description:
+      name: fixnum
+      sha256: b6dc7065e46c974bc7c5f143080a6764ec7a4be6da1285ececdc37be96de53be
+      url: "https://pub.dev"
+    source: hosted
+    version: "1.1.1"
   flutter:
     dependency: "direct main"
     description: flutter
@@ -120,6 +208,22 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "2.0.0"
+  http:
+    dependency: transitive
+    description:
+      name: http
+      sha256: "87721a4a50b19c7f1d49001e51409bddc46303966ce89a65af4f4e6004896412"
+      url: "https://pub.dev"
+    source: hosted
+    version: "1.6.0"
+  http_parser:
+    dependency: transitive
+    description:
+      name: http_parser
+      sha256: "178d74305e7866013777bab2c3d8726205dc5a4dd935297175b19a23a2e66571"
+      url: "https://pub.dev"
+    source: hosted
+    version: "4.1.2"
   jni:
     dependency: transitive
     description:
@@ -517,6 +621,14 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "1.4.0"
+  uuid:
+    dependency: transitive
+    description:
+      name: uuid
+      sha256: "1fef9e8e11e2991bb773070d4656b7bd5d850967a2456cfc83cf47925ba79489"
+      url: "https://pub.dev"
+    source: hosted
+    version: "4.5.3"
   vector_math:
     dependency: transitive
     description:
@@ -525,6 +637,22 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "2.2.0"
+  vibration:
+    dependency: "direct main"
+    description:
+      name: vibration
+      sha256: "9bb06614c69260f8bd11c80fe01ed7988905cf00e3417d656c2647e41f261d87"
+      url: "https://pub.dev"
+    source: hosted
+    version: "3.1.8"
+  vibration_platform_interface:
+    dependency: transitive
+    description:
+      name: vibration_platform_interface
+      sha256: "258c273268f8aa40c88d29741137c536874a738779b92ddb8aa32ed093721ec5"
+      url: "https://pub.dev"
+    source: hosted
+    version: "0.1.2"
   vm_service:
     dependency: transitive
     description:
@@ -541,6 +669,22 @@ packages:
       url: "https://pub.dev"
     source: hosted
     version: "1.1.1"
+  win32:
+    dependency: transitive
+    description:
+      name: win32
+      sha256: ba6f4bba816c8d7e3c1580e170f3786d216951cc6b94babc3b814c08d2cb2738
+      url: "https://pub.dev"
+    source: hosted
+    version: "6.3.0"
+  win32_registry:
+    dependency: transitive
+    description:
+      name: win32_registry
+      sha256: "73b1d78920a9d6e03f8b4e43e612b87bf3152a0e5c5e5150267762b7c4116904"
+      url: "https://pub.dev"
+    source: hosted
+    version: "3.0.3"
   xdg_directories:
     dependency: transitive
     description:

stronglift_replacement/workout_app/pubspec.yaml

@@ -14,6 +14,8 @@ dependencies:
   sqflite: ^2.4.2
   path_provider: ^2.1.5
   shared_preferences: ^2.5.3
+  audioplayers: ^6.4.0
+  vibration: ^3.1.0
   permission_handler: ^12.0.0
 
 dev_dependencies:
@@ -23,3 +25,5 @@ dev_dependencies:
 
 flutter:
   uses-material-design: true
+  assets:
+    - assets/sounds/break_end.mp3