diff --git a/docs/plans/2026-10-22-transcode-progress-fix.md b/docs/plans/2026-10-22-transcode-progress-fix.md
new file mode 100644
index 0000000..3ad3f3a
--- /dev/null
+++ b/docs/plans/2026-10-22-transcode-progress-fix.md
@@ -0,0 +1,29 @@
+# 转码错误截断与进度上报
+
+## 问题
+
+- ffmpeg 错误输出超过 `error_msg varchar(500)`，失败回写 UPDATE 再次失败，
+  任务停在 RUNNING/0。
+- worker 未解析 ffmpeg progress，前端只能看到 0。
+- 缺少 RUNNING 超时收口。
+
+## 修复
+
+1. SQL patch 将 transcode_task/media_thumbnail 的 error_msg 改为 TEXT，可重复执行。
+2. 新增统一错误消息截断，最多保留 500 字符并附总长度；即使补丁尚未执行，
+   也不会超过旧 varchar(500) 限制。
+3. ffmpeg 使用 `-progress` 临时文件，worker 节流为约 1 秒写 transcode_task.progress。
+4. rendition 阶段映射 0-90%，封面/缩略图 90-99%，成功后 100。
+5. 失败保留最后进度；RUNNING 超过 10 分钟无 updated_at 变化标记 FAILED。
+6. 手动重转复用最新任务，SUCCESS/FAILED/CANCELED 原地重置为 QUEUED、progress=0。
+7. 成功写 rendition 前替换同媒资旧产物，避免重复重转唯一键冲突。
+
+## 风险
+
+- 进度写入只允许 RUNNING 状态，避免覆盖已完成/失败状态。
+- 历史僵尸任务由 worker 下一轮自动收口，无需手工 SQL。
+
+## 验证
+
+- 错误截断、进度更新、僵尸重置、重复触发幂等测试。
+- `mvn -pl fruitshorts-module-media,fruitshorts-transcode-worker test`。
diff --git a/docs/plans/PROGRESS.md b/docs/plans/PROGRESS.md
index d96fb64..daefa51 100644
--- a/docs/plans/PROGRESS.md
+++ b/docs/plans/PROGRESS.md
@@ -25549,3 +25549,79 @@ $ mvn -pl fruitshorts-admin-api -am test
 
 解读：精度字符串、空态、video_url 反查命中、文件存在补登记及原有转码链全部通过。
 
+## 2026-10-22 转码错误截断与进度上报
+
+- 分支：`feature/transcode-progress-fix`
+- 基线：`develop` / `origin/develop` = `f9bc6ee`
+- 计划：`docs/plans/2026-10-22-transcode-progress-fix.md`
+
+现场根因已确认：ffmpeg 错误信息超过 error_msg varchar(500)，回写失败使任务
+停留在 RUNNING/0；同时现有 runner 未解析 ffmpeg progress，缺少 RUNNING 超时自愈。
+
+### TDD 红测
+
+```text
+$ mvn -pl fruitshorts-transcode-worker -am \
+  -Dtest=TranscodeServiceTriggerTest,TranscodeWorkerTest,FfmpegTranscodeRunnerSmokeTest \
+  -Dsurefire.failIfNoSpecifiedTests=false test
+[ERROR] TranscodeRequest 找不到 progressListener
+[ERROR] 找不到符号: 方法 updateProgress(Long,int)
+[ERROR] 找不到符号: 方法 recoverStaleRunningTasks()
+[INFO] BUILD FAILURE
+```
+
+解读：红测先锁定进度回调、进度落库和僵尸自愈接口，生产代码尚未实现。
+
+### 实现
+
+- error_msg 写库前统一截断为最多 500 字符，附 `truncated,total=...`；
+  即使数据库补丁尚未执行，也不会超过旧 varchar(500)。
+- ffmpeg 使用临时 `-progress` 文件，每 500ms 解析 out_time，
+  worker 最多每秒写一次 transcode_task.progress；只更新 RUNNING 状态。
+- rendition 阶段映射 0-90%，封面/缩略图 90-99%，成功事务置 100；
+  失败保留最后进度。
+- RUNNING 且 updated_at 超过 10 分钟未变化时自动标记 FAILED。
+- 手动重转复用最新任务，SUCCESS/FAILED/CANCELED 均原任务重置为 QUEUED、progress=0。
+- 成功写 rendition 前删除同媒资旧产物，避免重复重转唯一键冲突。
+- 聚合 VO 和任务 VO 增加 updatedAt，供前端展示最近更新时间。
+
+### SQL 补丁
+
+文件：`sql/patch-2026-10-22-transcode-error-msg.sql`
+
+PM 按项目现有 patch 方式执行（本任务未执行数据库变更），例如使用项目当前
+PostgreSQL 连接串：
+
+```text
+$ psql "$DB_URL" -f sql/patch-2026-10-22-transcode-error-msg.sql
+```
+
+脚本只将 `transcode_task.error_msg` 与 `media_thumbnail.error_msg`
+改为 TEXT，可重复执行。
+
+### 定向测试
+
+```text
+$ mvn -pl fruitshorts-transcode-worker -am \
+  -Dtest=TranscodeServiceTriggerTest,TranscodeWorkerTest,FfmpegTranscodeRunnerSmokeTest \
+  -Dsurefire.failIfNoSpecifiedTests=false test
+[INFO] Tests run: 16, Failures: 0, Errors: 0, Skipped: 0
+[INFO] BUILD SUCCESS
+```
+
+### 最终门禁
+
+```text
+$ mvn -pl fruitshorts-module-media,fruitshorts-transcode-worker test
+[INFO] Tests run: 8, Failures: 0, Errors: 0, Skipped: 0
+[INFO] Tests run: 39, Failures: 0, Errors: 0, Skipped: 0
+[INFO] BUILD SUCCESS
+
+$ mvn -pl fruitshorts-admin-api -am test
+[INFO] Tests run: 53, Failures: 0, Errors: 0, Skipped: 0
+[INFO] BUILD SUCCESS
+```
+
+解读：真实 ffmpeg smoke 已有进度回调且达到 90% 阶段点；长错误截断、
+进度更新、僵尸任务收口、重复触发复用均通过。
+
diff --git a/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminService.java b/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminService.java
index 1a5bfd7..914f9d2 100644
--- a/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminService.java
+++ b/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminService.java
@@ -65,6 +65,7 @@ public class EpisodeTranscodeAdminService {
             result.setProgress(0);
             result.setRetryCount(0);
             result.setErrorMsg("");
+            result.setUpdatedAt(episode.getUpdatedAt());
             return result;
         }
         result.setTaskId(idString(task.getId()));
@@ -72,6 +73,7 @@ public class EpisodeTranscodeAdminService {
         result.setProgress(task.getProgress());
         result.setRetryCount(task.getRetryCount());
         result.setErrorMsg(task.getErrorMsg());
+        result.setUpdatedAt(task.getUpdatedAt());
         return result;
     }
 
diff --git a/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/vo/EpisodeTranscodeRespVO.java b/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/vo/EpisodeTranscodeRespVO.java
index 6399012..8a5f08f 100644
--- a/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/vo/EpisodeTranscodeRespVO.java
+++ b/fruitshorts-admin-api/src/main/java/com/fruitshorts/admin/vo/EpisodeTranscodeRespVO.java
@@ -7,6 +7,7 @@ import com.fruitshorts.media.vo.MediaThumbnailRespVO;
 import io.swagger.v3.oas.annotations.media.Schema;
 import lombok.Data;
 
+import java.time.LocalDateTime;
 import java.util.List;
 
 /** 后台剧集编辑页一次性获取的转码状态。 */
@@ -21,6 +22,7 @@ public class EpisodeTranscodeRespVO {
     private Integer progress;
     private Integer retryCount;
     private String errorMsg;
+    private LocalDateTime updatedAt;
     private List<MediaRenditionRespVO> renditions = List.of();
     private MediaThumbnailRespVO thumbnails;
 }
diff --git a/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/controller/EpisodeTranscodeContractTest.java b/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/controller/EpisodeTranscodeContractTest.java
index d05650d..f75b5f7 100644
--- a/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/controller/EpisodeTranscodeContractTest.java
+++ b/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/controller/EpisodeTranscodeContractTest.java
@@ -9,6 +9,8 @@ import org.junit.jupiter.api.BeforeEach;
 import org.junit.jupiter.api.Test;
 import org.springframework.test.web.servlet.MockMvc;
 
+import java.time.LocalDateTime;
+
 import static org.mockito.BDDMockito.given;
 import static org.mockito.Mockito.mock;
 import static org.springframework.test.web.servlet.request.MockMvcRequestBuilders.get;
@@ -38,6 +40,7 @@ class EpisodeTranscodeContractTest {
         vo.setTaskId(taskId);
         vo.setStatus("SUCCESS");
         vo.setProgress(100);
+        vo.setUpdatedAt(LocalDateTime.of(2026, 10, 22, 15, 10));
         given(service.detail(Long.parseLong(episodeId))).willReturn(vo);
 
         mockMvc.perform(get("/admin/episodes/" + episodeId + "/transcode"))
@@ -47,7 +50,8 @@ class EpisodeTranscodeContractTest {
                 .andExpect(jsonPath("$.data.mediaAssetId").value(mediaAssetId))
                 .andExpect(jsonPath("$.data.taskId").value(taskId))
                 .andExpect(jsonPath("$.data.status").value("SUCCESS"))
-                .andExpect(jsonPath("$.data.progress").value(100));
+                .andExpect(jsonPath("$.data.progress").value(100))
+                .andExpect(jsonPath("$.data.updatedAt").value("2026-10-22T15:10:00"));
     }
 
     @Test
diff --git a/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminServiceTest.java b/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminServiceTest.java
index b7f3d88..f231237 100644
--- a/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminServiceTest.java
+++ b/fruitshorts-admin-api/src/test/java/com/fruitshorts/admin/service/EpisodeTranscodeAdminServiceTest.java
@@ -11,6 +11,7 @@ import org.junit.jupiter.api.BeforeEach;
 import org.junit.jupiter.api.Test;
 
 import java.util.List;
+import java.time.LocalDateTime;
 
 import static org.assertj.core.api.Assertions.assertThat;
 import static org.mockito.BDDMockito.given;
@@ -77,6 +78,7 @@ class EpisodeTranscodeAdminServiceTest {
         task.setMediaAssetId(MEDIA_ASSET_ID);
         task.setStatus("SUCCESS");
         task.setProgress(100);
+        task.setUpdatedAt(LocalDateTime.of(2026, 10, 22, 15, 10));
         given(outputService.latestTask(MEDIA_ASSET_ID)).willReturn(task);
 
         var result = service.detail(EPISODE_ID);
@@ -84,6 +86,7 @@ class EpisodeTranscodeAdminServiceTest {
         assertThat(result.getEpisodeId()).isEqualTo("2113150431755636737");
         assertThat(result.getMediaAssetId()).isEqualTo("2113150398670966786");
         assertThat(result.getTaskId()).isEqualTo("2113150398935207938");
+        assertThat(result.getUpdatedAt()).isEqualTo(task.getUpdatedAt());
     }
 
     @Test
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/ThumbnailRecordService.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/ThumbnailRecordService.java
index 9c3baaa..965ed99 100644
--- a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/ThumbnailRecordService.java
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/ThumbnailRecordService.java
@@ -33,6 +33,7 @@ public class ThumbnailRecordService {
                         .last("limit 1"));
         thumbnail.setDramaId(task.getDramaId() == null ? 0L : task.getDramaId());
         thumbnail.setEpisodeId(episodeId);
+        thumbnail.setErrorMsg(TranscodeErrorTruncator.truncate(thumbnail.getErrorMsg()));
         if (existing == null) {
             mediaThumbnailMapper.insert(thumbnail);
             return;
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/TranscodeErrorTruncator.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/TranscodeErrorTruncator.java
new file mode 100644
index 0000000..38b4170
--- /dev/null
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/TranscodeErrorTruncator.java
@@ -0,0 +1,23 @@
+// Author: fruit.com.cn
+
+package com.fruitshorts.media.service;
+
+/** 转码错误消息统一截断，避免数据库写入失败。 */
+public final class TranscodeErrorTruncator {
+
+    public static final int MAX_ERROR_CHARS = 500;
+    private static final String EMPTY = "";
+    private static final String TRUNCATED_TEMPLATE = "…(truncated, total=%d chars)";
+
+    private TranscodeErrorTruncator() {
+    }
+
+    public static String truncate(String message) {
+        if (message == null || message.isEmpty() || message.length() <= MAX_ERROR_CHARS) {
+            return message == null ? EMPTY : message;
+        }
+        String suffix = String.format(TRUNCATED_TEMPLATE, message.length());
+        int prefixLength = Math.max(0, MAX_ERROR_CHARS - suffix.length());
+        return message.substring(0, prefixLength) + suffix;
+    }
+}
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/TranscodeService.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/TranscodeService.java
index a59f135..190d4bd 100644
--- a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/TranscodeService.java
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/TranscodeService.java
@@ -42,6 +42,10 @@ public class TranscodeService {
     public static final String STATUS_FAILED = "FAILED";
     /** 失败重试上限（`backend-design-phase1.md` §7.2：失败重试 3 次并记录原因）。 */
     public static final int MAX_RETRY = 3;
+    public static final int STALE_RUNNING_MINUTES = 10;
+    private static final int MAX_RUNNING_PROGRESS = 99;
+    private static final String STALE_RUNNING_REASON =
+            "任务 RUNNING 超过 10 分钟无进度更新，已自动标记失败，请重新转码";
 
     private final TranscodeTaskMapper transcodeTaskMapper;
     private final MediaRenditionMapper mediaRenditionMapper;
@@ -83,7 +87,7 @@ public class TranscodeService {
             return response(latest.getId(), latest.getStatus());
         }
         if (latest != null && isRetryable(latest.getStatus())) {
-            resetFailedTask(latest, sourceUrl);
+            resetTaskForRetry(latest, sourceUrl);
             return response(latest.getId(), STATUS_QUEUED);
         }
 
@@ -162,6 +166,8 @@ public class TranscodeService {
     public void succeed(Long taskId, List<MediaRendition> renditions,
                         MediaThumbnail thumbnail) {
         TranscodeTask task = getExisting(taskId);
+        mediaRenditionMapper.delete(Wrappers.<MediaRendition>lambdaQuery()
+                .eq(MediaRendition::getMediaAssetId, task.getMediaAssetId()));
         for (MediaRendition rendition : renditions) {
             rendition.setMediaAssetId(task.getMediaAssetId());
             rendition.setDramaId(task.getDramaId());
@@ -173,10 +179,10 @@ public class TranscodeService {
         if (thumbnail != null) {
             try {
                 thumbnailRecordService.upsert(task, thumbnail);
-                thumbnailError = thumbnail.getErrorMsg() == null
-                        ? "" : thumbnail.getErrorMsg();
+                thumbnailError = TranscodeErrorTruncator.truncate(thumbnail.getErrorMsg());
             } catch (Exception ex) {
-                thumbnailError = "缩略图登记失败：" + exceptionMessage(ex);
+                thumbnailError = TranscodeErrorTruncator.truncate(
+                        "缩略图登记失败：" + exceptionMessage(ex));
                 log.warn("缩略图登记失败 task={}：{}", taskId, ex.getMessage());
             }
         }
@@ -202,12 +208,35 @@ public class TranscodeService {
             task.setStatus(STATUS_QUEUED);
         }
         task.setRetryCount(retry + 1);
-        task.setErrorMsg(errorMessage == null ? "" : errorMessage);
+        task.setErrorMsg(TranscodeErrorTruncator.truncate(errorMessage));
         task.setFinishedAt(LocalDateTime.now());
         transcodeTaskMapper.updateById(task);
         return task.getStatus();
     }
 
+    /** worker 实时上报 RUNNING 任务进度，最多到 99，100 由成功事务统一写入。 */
+    public void updateProgress(Long taskId, int progress) {
+        if (taskId == null) {
+            return;
+        }
+        int safeProgress = Math.min(MAX_RUNNING_PROGRESS, Math.max(0, progress));
+        transcodeTaskMapper.update(null, Wrappers.<TranscodeTask>lambdaUpdate()
+                .eq(TranscodeTask::getId, taskId)
+                .eq(TranscodeTask::getStatus, STATUS_RUNNING)
+                .set(TranscodeTask::getProgress, safeProgress));
+    }
+
+    /** RUNNING 超过阈值且 updated_at 长期未变时自动收口，避免僵尸任务永久占位。 */
+    public int recoverStaleRunningTasks() {
+        LocalDateTime now = LocalDateTime.now();
+        return transcodeTaskMapper.update(null, Wrappers.<TranscodeTask>lambdaUpdate()
+                .eq(TranscodeTask::getStatus, STATUS_RUNNING)
+                .lt(TranscodeTask::getUpdatedAt, now.minusMinutes(STALE_RUNNING_MINUTES))
+                .set(TranscodeTask::getStatus, STATUS_FAILED)
+                .set(TranscodeTask::getErrorMsg, STALE_RUNNING_REASON)
+                .set(TranscodeTask::getFinishedAt, now));
+    }
+
     public List<MediaRendition> listRenditions(Long episodeId) {
         return mediaRenditionMapper.selectList(Wrappers.<MediaRendition>lambdaQuery()
                 .eq(MediaRendition::getEpisodeId, episodeId)
@@ -314,14 +343,16 @@ public class TranscodeService {
     }
 
     private boolean isRetryable(String status) {
-        return STATUS_FAILED.equals(status) || "CANCELED".equals(status);
+        return STATUS_SUCCESS.equals(status)
+                || STATUS_FAILED.equals(status) || "CANCELED".equals(status);
     }
 
-    private void resetFailedTask(TranscodeTask task, String sourceUrl) {
+    private void resetTaskForRetry(TranscodeTask task, String sourceUrl) {
         boolean hasSource = sourceUrl != null && !sourceUrl.isBlank();
         transcodeTaskMapper.update(null, Wrappers.<TranscodeTask>lambdaUpdate()
                 .eq(TranscodeTask::getId, task.getId())
-                .in(TranscodeTask::getStatus, List.of(STATUS_FAILED, "CANCELED"))
+                .in(TranscodeTask::getStatus,
+                        List.of(STATUS_SUCCESS, STATUS_FAILED, "CANCELED"))
                 .set(TranscodeTask::getStatus, STATUS_QUEUED)
                 .set(TranscodeTask::getProgress, 0)
                 .set(TranscodeTask::getRetryCount, 0)
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/FfmpegProgressMonitor.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/FfmpegProgressMonitor.java
new file mode 100644
index 0000000..9c950f4
--- /dev/null
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/FfmpegProgressMonitor.java
@@ -0,0 +1,105 @@
+// Author: fruit.com.cn
+
+package com.fruitshorts.media.service.transcode;
+
+import com.fruitshorts.common.exception.ErrorCode;
+import com.fruitshorts.common.exception.ServiceException;
+
+import java.io.IOException;
+import java.nio.charset.StandardCharsets;
+import java.nio.file.Files;
+import java.nio.file.Path;
+import java.util.concurrent.atomic.AtomicInteger;
+import java.util.function.IntConsumer;
+
+/** 解析 ffmpeg -progress 临时文件并节流上报。 */
+final class FfmpegProgressMonitor {
+
+    private static final long MICROS_PER_SECOND = 1_000_000L;
+
+    private FfmpegProgressMonitor() {
+    }
+
+    static Path createTempFile() {
+        try {
+            return Files.createTempFile("fruitshorts-ffmpeg-progress-", ".log");
+        } catch (IOException ex) {
+            throw new ServiceException(ErrorCode.INTERNAL_ERROR,
+                    "创建 ffmpeg 进度文件失败：" + ex.getMessage());
+        }
+    }
+
+    static void report(
+            Path progressFile, int durationSec,
+            AtomicInteger lastReported, IntConsumer listener) {
+        if (!Files.isRegularFile(progressFile)) {
+            return;
+        }
+        String content;
+        try {
+            content = Files.readString(progressFile, StandardCharsets.UTF_8);
+        } catch (IOException ex) {
+            return;
+        }
+        long microseconds = extractOutTimeMicros(content);
+        if (microseconds < 0) {
+            return;
+        }
+        int percent = durationSec <= 0 ? 0
+                : (int) Math.min(100, microseconds * 100 / (durationSec * MICROS_PER_SECOND));
+        if (percent > lastReported.get()) {
+            lastReported.set(percent);
+            listener.accept(percent);
+        }
+    }
+
+    static void deleteQuietly(Path path) {
+        if (path == null) {
+            return;
+        }
+        try {
+            Files.deleteIfExists(path);
+        } catch (IOException ignored) {
+            // 临时进度文件删不掉不影响业务结果
+        }
+    }
+
+    private static long extractOutTimeMicros(String content) {
+        long result = -1L;
+        for (String line : content.split("\\R")) {
+            String[] pair = line.trim().split("=", 2);
+            if (pair.length != 2) {
+                continue;
+            }
+            if ("out_time_us".equals(pair[0]) || "out_time_ms".equals(pair[0])) {
+                result = Math.max(result, parseLong(pair[1]));
+            } else if ("out_time".equals(pair[0])) {
+                result = Math.max(result, parseTimestampMicros(pair[1]));
+            }
+        }
+        return result;
+    }
+
+    private static long parseTimestampMicros(String timestamp) {
+        String[] parts = timestamp.trim().split(":");
+        if (parts.length != 3) {
+            return -1L;
+        }
+        try {
+            double seconds = Integer.parseInt(parts[0]) * 3600.0
+                    + Integer.parseInt(parts[1]) * 60.0
+                    + Double.parseDouble(parts[2]);
+            return Math.round(seconds * MICROS_PER_SECOND);
+        } catch (NumberFormatException ex) {
+            return -1L;
+        }
+    }
+
+    private static long parseLong(String value) {
+        try {
+            return Long.parseLong(value.trim());
+        } catch (NumberFormatException ex) {
+            return -1L;
+        }
+    }
+}
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/FfmpegTranscodeRunner.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/FfmpegTranscodeRunner.java
index 3f911cf..174bce7 100644
--- a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/FfmpegTranscodeRunner.java
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/FfmpegTranscodeRunner.java
@@ -15,6 +15,8 @@ import java.util.ArrayList;
 import java.util.Comparator;
 import java.util.List;
 import java.util.concurrent.TimeUnit;
+import java.util.concurrent.atomic.AtomicInteger;
+import java.util.function.IntConsumer;
 import java.util.stream.Stream;
 
 /**
@@ -35,6 +37,11 @@ public class FfmpegTranscodeRunner implements TranscodeRunner {
     private static final String VARIANT_PLAYLIST = "index.m3u8";
     private static final String POSTER_FILE = "poster.jpg";
     private static final int STDERR_TAIL = 800;
+    private static final int TRANSCODE_PROGRESS_END = 90;
+    private static final int POSTER_PROGRESS_START = 92;
+    private static final int POSTER_PROGRESS_END = 95;
+    private static final int THUMBNAIL_PROGRESS_END = 99;
+    private static final long PROCESS_POLL_MILLIS = 500;
     private final FfmpegThumbnailGenerator thumbnailGenerator = new FfmpegThumbnailGenerator();
 
     @Override
@@ -46,14 +53,23 @@ public class FfmpegTranscodeRunner implements TranscodeRunner {
         createDirectories(request.outputDir());
         int durationSec = probeDuration(request);
         SourceDimensions source = probeSourceDimensions(request);
+        reportProgress(request.progressListener(), 1);
 
         List<ProducedRendition> renditions = new ArrayList<>(request.ladder().size());
-        for (LadderRung rung : request.ladder()) {
-            renditions.add(transcodeRung(request, rung, source));
+        int totalRungs = Math.max(1, request.ladder().size());
+        for (int index = 0; index < request.ladder().size(); index++) {
+            int start = index * TRANSCODE_PROGRESS_END / totalRungs;
+            int end = (index + 1) * TRANSCODE_PROGRESS_END / totalRungs;
+            renditions.add(transcodeRung(
+                    request, request.ladder().get(index), source, durationSec, start, end));
         }
+        reportProgress(request.progressListener(), POSTER_PROGRESS_START);
         writeMasterPlaylist(request, renditions);
         ProducedRendition poster = extractPoster(request);
+        reportProgress(request.progressListener(), POSTER_PROGRESS_END);
+        reportProgress(request.progressListener(), 96);
         ProducedThumbnail thumbnail = thumbnailGenerator.generate(request, durationSec);
+        reportProgress(request.progressListener(), THUMBNAIL_PROGRESS_END);
         log.info("转码完成 task={}：{} 档 HLS + 封面 + 缩略图状态={}，时长 {}s",
                 request.taskId(), renditions.size(),
                 thumbnail == null ? "DISABLED" : thumbnail.status(), durationSec);
@@ -62,7 +78,8 @@ public class FfmpegTranscodeRunner implements TranscodeRunner {
     }
 
     private ProducedRendition transcodeRung(
-            TranscodeRequest request, LadderRung rung, SourceDimensions source) {
+            TranscodeRequest request, LadderRung rung, SourceDimensions source,
+            int durationSec, int progressStart, int progressEnd) {
         String relativeDir = rung.quality() + "/";
         Path rungDir = request.outputDir().resolve(rung.quality());
         createDirectories(rungDir);
@@ -70,8 +87,10 @@ public class FfmpegTranscodeRunner implements TranscodeRunner {
         String scaleFilter = source.landscape()
                 ? "scale=-2:" + shortEdge + ":flags=lanczos,setsar=1"
                 : "scale=" + shortEdge + ":-2:flags=lanczos,setsar=1";
+        Path progressFile = FfmpegProgressMonitor.createTempFile();
         List<String> command = List.of(
                 request.ffmpegPath(), "-y",
+                "-progress", progressFile.toString(), "-nostats",
                 "-i", request.sourceFile().toString(),
                 // 按源方向只用短边定档；-2 保证自动推导的一边为偶数，setsar=1 避免播放器再次拉伸
                 "-vf", scaleFilter,
@@ -85,7 +104,15 @@ public class FfmpegTranscodeRunner implements TranscodeRunner {
                 "-hls_playlist_type", "vod",
                 "-hls_segment_filename", rungDir.resolve("seg_%03d.ts").toString(),
                 rungDir.resolve(VARIANT_PLAYLIST).toString());
-        runProcess(command, request.timeoutSeconds(), "转码 " + rung.quality() + " 失败");
+        try {
+            runProcessWithProgress(command, request.timeoutSeconds(),
+                    "转码 " + rung.quality() + " 失败", progressFile, durationSec,
+                    rawProgress -> reportProgress(request.progressListener(),
+                            mapProgress(rawProgress, progressStart, progressEnd)));
+            reportProgress(request.progressListener(), progressEnd);
+        } finally {
+            FfmpegProgressMonitor.deleteQuietly(progressFile);
+        }
 
         Path playlist = rungDir.resolve(VARIANT_PLAYLIST);
         if (!Files.exists(playlist)) {
@@ -99,6 +126,17 @@ public class FfmpegTranscodeRunner implements TranscodeRunner {
                 sizeOf(rungDir), countSegments(rungDir));
     }
 
+    private int mapProgress(int rawProgress, int start, int end) {
+        int safe = Math.min(100, Math.max(0, rawProgress));
+        return start + (end - start) * safe / 100;
+    }
+
+    private void reportProgress(IntConsumer listener, int progress) {
+        if (listener != null) {
+            listener.accept(Math.min(99, Math.max(0, progress)));
+        }
+    }
+
     private int effectiveShortEdge(LadderRung rung, SourceDimensions source) {
         int rungShortEdge = Math.min(rung.width(), rung.height());
         int capped = Math.min(rungShortEdge, source.shortEdge());
@@ -247,6 +285,47 @@ public class FfmpegTranscodeRunner implements TranscodeRunner {
         }
     }
 
+    /** 运行 ffmpeg 并轮询 -progress 文件，把 out_time 映射成 0-100。 */
+    private String runProcessWithProgress(
+            List<String> command, int timeoutSeconds, String errorPrefix,
+            Path progressFile, int durationSec, IntConsumer listener) {
+        Path logFile = null;
+        try {
+            logFile = Files.createTempFile("fruitshorts-ffmpeg-", ".log");
+            Process process = new ProcessBuilder(command)
+                    .redirectErrorStream(true)
+                    .redirectOutput(logFile.toFile())
+                    .start();
+            AtomicInteger lastReported = new AtomicInteger(-1);
+            long deadline = System.currentTimeMillis() + timeoutSeconds * 1000L;
+            while (!process.waitFor(PROCESS_POLL_MILLIS, TimeUnit.MILLISECONDS)) {
+                FfmpegProgressMonitor.report(progressFile, durationSec, lastReported, listener);
+                if (System.currentTimeMillis() > deadline) {
+                    process.destroyForcibly();
+                    throw new ServiceException(ErrorCode.INTERNAL_ERROR,
+                            errorPrefix + "：超时（" + timeoutSeconds + "s）");
+                }
+            }
+            FfmpegProgressMonitor.report(progressFile, durationSec, lastReported, listener);
+            String output = Files.readString(logFile, StandardCharsets.UTF_8);
+            if (process.exitValue() != 0) {
+                throw new ServiceException(ErrorCode.INTERNAL_ERROR,
+                        errorPrefix + "：" + tail(output));
+            }
+            return output;
+        } catch (ServiceException ex) {
+            throw ex;
+        } catch (IOException ex) {
+            throw new ServiceException(ErrorCode.INTERNAL_ERROR,
+                    errorPrefix + "：无法执行 ffmpeg（" + ex.getMessage() + "）");
+        } catch (InterruptedException ex) {
+            Thread.currentThread().interrupt();
+            throw new ServiceException(ErrorCode.INTERNAL_ERROR, errorPrefix + "：被中断");
+        } finally {
+            FfmpegProgressMonitor.deleteQuietly(logFile);
+        }
+    }
+
     /**
      * 起进程并等结果；非 0 退出把输出尾部带进异常，方便定位是片源问题还是参数问题。
      *
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeRunner.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeRunner.java
index 814b096..8a1decf 100644
--- a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeRunner.java
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeRunner.java
@@ -4,6 +4,7 @@ package com.fruitshorts.media.service.transcode;
 
 import java.nio.file.Path;
 import java.util.List;
+import java.util.function.IntConsumer;
 
 /**
  * 转码执行端口：把"调 ffmpeg 出多码率 HLS + 封面"封在一层后面。
@@ -30,14 +31,25 @@ public interface TranscodeRunner {
     record TranscodeRequest(Long taskId, Path sourceFile, Path outputDir, String objectKeyPrefix,
                             List<LadderRung> ladder, String ffmpegPath, String ffprobePath,
                             int segmentSeconds, int posterSecond, int timeoutSeconds,
-                            SpriteOptions sprite) {
+                            SpriteOptions sprite, IntConsumer progressListener) {
+
+        public TranscodeRequest(Long taskId, Path sourceFile, Path outputDir, String objectKeyPrefix,
+                                List<LadderRung> ladder, String ffmpegPath, String ffprobePath,
+                                int segmentSeconds, int posterSecond, int timeoutSeconds,
+                                SpriteOptions sprite) {
+            this(taskId, sourceFile, outputDir, objectKeyPrefix, ladder, ffmpegPath, ffprobePath,
+                    segmentSeconds, posterSecond, timeoutSeconds, sprite, ignored -> {
+                    });
+        }
 
         /** 兼容未启用缩略图的既有调用。 */
         public TranscodeRequest(Long taskId, Path sourceFile, Path outputDir, String objectKeyPrefix,
                                 List<LadderRung> ladder, String ffmpegPath, String ffprobePath,
                                 int segmentSeconds, int posterSecond, int timeoutSeconds) {
             this(taskId, sourceFile, outputDir, objectKeyPrefix, ladder, ffmpegPath, ffprobePath,
-                    segmentSeconds, posterSecond, timeoutSeconds, SpriteOptions.disabled());
+                    segmentSeconds, posterSecond, timeoutSeconds, SpriteOptions.disabled(),
+                    ignored -> {
+                    });
         }
     }
 
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeWorker.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeWorker.java
index 0e897ba..5b7b293 100644
--- a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeWorker.java
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/service/transcode/TranscodeWorker.java
@@ -9,6 +9,7 @@ import com.fruitshorts.media.service.MediaService;
 import com.fruitshorts.media.service.MediaStorageService;
 import com.fruitshorts.media.service.MediaTranscodeProfileService;
 import com.fruitshorts.media.service.EpisodeTranscodeCompletionPort;
+import com.fruitshorts.media.service.TranscodeErrorTruncator;
 import com.fruitshorts.media.service.TranscodeService;
 import lombok.RequiredArgsConstructor;
 import lombok.extern.slf4j.Slf4j;
@@ -19,6 +20,8 @@ import org.springframework.stereotype.Component;
 import java.nio.file.Path;
 import java.util.ArrayList;
 import java.util.List;
+import java.util.concurrent.atomic.AtomicLong;
+import java.util.function.IntConsumer;
 
 /**
  * 转码 worker：消费 `transcode_task`，产出多码率 HLS + 封面。
@@ -38,6 +41,8 @@ import java.util.List;
 @ConditionalOnProperty(name = "fruitshorts.media.transcode.worker-enabled", havingValue = "true")
 public class TranscodeWorker {
 
+    private static final long PROGRESS_WRITE_INTERVAL_MS = 1000L;
+
     private final TranscodeService transcodeService;
     private final MediaService mediaService;
     private final MediaStorageService storageService;
@@ -49,6 +54,10 @@ public class TranscodeWorker {
     @Scheduled(fixedDelayString = "${fruitshorts.media.transcode.poll-delay-ms:5000}")
     public void poll() {
         try {
+            int recovered = transcodeService.recoverStaleRunningTasks();
+            if (recovered > 0) {
+                log.warn("已自动收口 {} 个超时 RUNNING 转码任务", recovered);
+            }
             processOne();
         } catch (Exception ex) {
             // 轮询里不能让异常逃出去，否则调度线程会被取消，整个 worker 静默停摆
@@ -82,7 +91,8 @@ public class TranscodeWorker {
                     task.getId(), sourceFile, outputDir, objectKeyPrefix, ladder(profile),
                     profileService.ffmpegPath(), profileService.ffprobePath(),
                     profile.getSegmentSeconds(), profileService.posterSecond(),
-                    profileService.timeoutSeconds(), spriteOptions(profile)));
+                    profileService.timeoutSeconds(), spriteOptions(profile),
+                    progressListener(task.getId())));
 
             transcodeService.succeed(task.getId(), toRenditions(result),
                     toThumbnail(task, result.thumbnail()));
@@ -140,6 +150,17 @@ public class TranscodeWorker {
                 sprite.getColumns(), sprite.getThumbWidth());
     }
 
+    private IntConsumer progressListener(Long taskId) {
+        AtomicLong lastWriteAt = new AtomicLong(0L);
+        return progress -> {
+            long now = System.currentTimeMillis();
+            if (now - lastWriteAt.get() >= PROGRESS_WRITE_INTERVAL_MS || progress >= 99) {
+                lastWriteAt.set(now);
+                transcodeService.updateProgress(taskId, progress);
+            }
+        };
+    }
+
     private MediaThumbnail toThumbnail(
             TranscodeTask task, TranscodeRunner.ProducedThumbnail produced) {
         if (produced == null) {
@@ -159,7 +180,7 @@ public class TranscodeWorker {
         thumbnail.setDurationSec(produced.durationSec());
         thumbnail.setSizeBytes(produced.sizeBytes());
         thumbnail.setStatus(produced.status());
-        thumbnail.setErrorMsg(produced.errorMessage());
+        thumbnail.setErrorMsg(TranscodeErrorTruncator.truncate(produced.errorMessage()));
         return thumbnail;
     }
 
@@ -169,7 +190,8 @@ public class TranscodeWorker {
             return;
         }
         if (MediaThumbnail.STATUS_FAILED.equals(thumbnail.status())) {
-            log.warn("主转码成功但缩略图失败：{}", thumbnail.errorMessage());
+            log.warn("主转码成功但缩略图失败：{}",
+                    TranscodeErrorTruncator.truncate(thumbnail.errorMessage()));
             return;
         }
         log.info("缩略图完成：{} 帧，{}x{}", thumbnail.frameCount(),
diff --git a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/vo/TranscodeTaskRespVO.java b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/vo/TranscodeTaskRespVO.java
index ac51407..dd6913d 100644
--- a/fruitshorts-module-media/src/main/java/com/fruitshorts/media/vo/TranscodeTaskRespVO.java
+++ b/fruitshorts-module-media/src/main/java/com/fruitshorts/media/vo/TranscodeTaskRespVO.java
@@ -26,6 +26,7 @@ public class TranscodeTaskRespVO {
     private LocalDateTime startedAt;
     private LocalDateTime finishedAt;
     private LocalDateTime createdAt;
+    private LocalDateTime updatedAt;
 
     public static TranscodeTaskRespVO from(TranscodeTask task) {
         if (task == null) {
@@ -45,6 +46,7 @@ public class TranscodeTaskRespVO {
         vo.setStartedAt(task.getStartedAt());
         vo.setFinishedAt(task.getFinishedAt());
         vo.setCreatedAt(task.getCreatedAt());
+        vo.setUpdatedAt(task.getUpdatedAt());
         return vo;
     }
 }
diff --git a/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/FfmpegTranscodeRunnerSmokeTest.java b/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/FfmpegTranscodeRunnerSmokeTest.java
index a0f9a43..532dbf6 100644
--- a/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/FfmpegTranscodeRunnerSmokeTest.java
+++ b/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/FfmpegTranscodeRunnerSmokeTest.java
@@ -12,6 +12,7 @@ import java.nio.file.Path;
 import java.util.Comparator;
 import java.util.List;
 import java.util.concurrent.TimeUnit;
+import java.util.concurrent.atomic.AtomicInteger;
 import java.util.stream.Stream;
 
 import static org.assertj.core.api.Assertions.assertThat;
@@ -40,13 +41,15 @@ class FfmpegTranscodeRunnerSmokeTest {
 
             Path output = work.resolve("out");
             TranscodeRunner runner = new FfmpegTranscodeRunner();
+            AtomicInteger maxProgress = new AtomicInteger();
             // 只跑两档（360p/480p）保持秒级；四档阶梯的逻辑在 TranscodeWorkerTest 里断言
             TranscodeRunner.TranscodeResult result = runner.run(new TranscodeRunner.TranscodeRequest(
                     1L, sample, output, "transcoded/smoke",
                     List.of(new TranscodeRunner.LadderRung("360p", 640, 360, 400, 64),
                             new TranscodeRunner.LadderRung("480p", 854, 480, 800, 64)),
                     ffmpeg, ffprobe, 2, 1, 120,
-                    new TranscodeRunner.SpriteOptions(true, 1, 10, 160)));
+                    new TranscodeRunner.SpriteOptions(true, 1, 10, 160),
+                    value -> maxProgress.accumulateAndGet(value, Math::max)));
 
             assertThat(Files.exists(output.resolve("master.m3u8"))).isTrue();
             assertThat(Files.exists(output.resolve("poster.jpg"))).isTrue();
@@ -60,6 +63,7 @@ class FfmpegTranscodeRunnerSmokeTest {
                 assertThat(rendition.sizeBytes()).isGreaterThan(0L);
             }
             assertThat(result.durationSec()).isBetween(1, 5);
+            assertThat(maxProgress.get()).isGreaterThanOrEqualTo(90);
             assertThat(result.thumbnail()).isNotNull();
             assertThat(result.thumbnail().status()).isEqualTo("READY");
             assertThat(result.thumbnail().thumbWidth()).isEqualTo(160);
diff --git a/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeServiceTriggerTest.java b/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeServiceTriggerTest.java
index f52e045..998de70 100644
--- a/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeServiceTriggerTest.java
+++ b/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeServiceTriggerTest.java
@@ -21,7 +21,6 @@ import org.junit.jupiter.api.Test;
 import static org.assertj.core.api.Assertions.assertThat;
 import static org.mockito.ArgumentMatchers.any;
 import static org.mockito.BDDMockito.given;
-import static org.mockito.Mockito.doAnswer;
 import static org.mockito.Mockito.mock;
 import static org.mockito.Mockito.never;
 import static org.mockito.Mockito.verify;
@@ -54,24 +53,22 @@ class TranscodeServiceTriggerTest {
     }
 
     @Test
-    void should_create_once_and_reuse_queued_task_when_retrying_successful_asset() {
+    void should_reset_completed_task_in_place_and_reuse_it_when_triggered_again() {
         TranscodeTask success = task(10L, TranscodeService.STATUS_SUCCESS);
         TranscodeTask queued = task(100L, TranscodeService.STATUS_QUEUED);
-        given(taskMapper.selectOne(any())).willReturn(success, null, queued);
-        doAnswer(invocation -> {
-            TranscodeTask inserted = invocation.getArgument(0);
-            inserted.setId(100L);
-            return 1;
-        }).when(taskMapper).insert(any(TranscodeTask.class));
+        queued.setId(10L);
+        given(taskMapper.selectOne(any())).willReturn(success, queued);
+        given(taskMapper.update(any(), any())).willReturn(1);
 
         TranscodeTriggerRespVO first = transcodeService.trigger(ASSET_ID, "/files/video.mp4");
         TranscodeTriggerRespVO second = transcodeService.trigger(ASSET_ID, "/files/video.mp4");
 
-        assertThat(first.getTaskId()).isEqualTo(100L);
+        assertThat(first.getTaskId()).isEqualTo(10L);
         assertThat(first.getStatus()).isEqualTo(TranscodeService.STATUS_QUEUED);
-        assertThat(second.getTaskId()).isEqualTo(100L);
+        assertThat(second.getTaskId()).isEqualTo(10L);
         assertThat(second.getStatus()).isEqualTo(TranscodeService.STATUS_QUEUED);
-        verify(taskMapper).insert(any(TranscodeTask.class));
+        verify(taskMapper, never()).insert(any(TranscodeTask.class));
+        verify(taskMapper).update(any(), any());
     }
 
     @Test
@@ -111,17 +108,39 @@ class TranscodeServiceTriggerTest {
         TranscodeTask running = task(41L, TranscodeService.STATUS_RUNNING);
         running.setRetryCount(2);
         given(taskMapper.selectById(41L)).willReturn(running);
+        String longReason = "ffmpeg 输出异常：" + "x".repeat(5000);
 
-        String status = transcodeService.fail(
-                41L, "ffmpeg 退出码 1：Invalid data found");
+        String status = transcodeService.fail(41L, longReason);
 
         assertThat(status).isEqualTo(TranscodeService.STATUS_FAILED);
         assertThat(running.getStatus()).isEqualTo(TranscodeService.STATUS_FAILED);
         assertThat(running.getRetryCount()).isEqualTo(3);
-        assertThat(running.getErrorMsg()).contains("Invalid data found");
+        assertThat(running.getErrorMsg()).contains("ffmpeg 输出异常");
+        assertThat(running.getErrorMsg()).contains("truncated");
+        assertThat(running.getErrorMsg()).contains("total=" + longReason.length());
+        assertThat(running.getErrorMsg().length()).isLessThanOrEqualTo(500);
         verify(taskMapper).updateById(running);
     }
 
+    @Test
+    void should_update_progress_only_for_running_task() {
+        given(taskMapper.update(any(), any())).willReturn(1);
+
+        transcodeService.updateProgress(51L, 46);
+
+        verify(taskMapper).update(any(), any());
+    }
+
+    @Test
+    void should_mark_stale_running_task_failed() {
+        given(taskMapper.update(any(), any())).willReturn(2);
+
+        int recovered = transcodeService.recoverStaleRunningTasks();
+
+        assertThat(recovered).isEqualTo(2);
+        verify(taskMapper).update(any(), any());
+    }
+
     private TranscodeTask task(Long id, String status) {
         TranscodeTask task = new TranscodeTask();
         task.setId(id);
diff --git a/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeWorkerTest.java b/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeWorkerTest.java
index dbb4588..0335614 100644
--- a/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeWorkerTest.java
+++ b/fruitshorts-transcode-worker/src/test/java/com/fruitshorts/worker/TranscodeWorkerTest.java
@@ -72,6 +72,7 @@ class TranscodeWorkerTest {
     @Test
     void should_register_renditions_and_mark_asset_ready_when_transcode_succeeds() {
         given(transcodeService.claimNext()).willReturn(queuedTask());
+        runner.progress = 45;
 
         assertThat(worker.processOne()).isTrue();
 
@@ -92,6 +93,7 @@ class TranscodeWorkerTest {
                 eq("/files/transcoded/88/poster.jpg"), eq(120));
         verify(episodeCompletionPort).markEpisodeReady(
                 12L, "/files/transcoded/88/master.m3u8", 120);
+        verify(transcodeService).updateProgress(TASK_ID, 45);
         verify(transcodeService, never()).fail(any(), anyString());
     }
 
@@ -110,11 +112,12 @@ class TranscodeWorkerTest {
     @Test
     void should_keep_main_transcode_successful_when_thumbnail_generation_fails() {
         given(transcodeService.claimNext()).willReturn(queuedTask());
+        String thumbnailError = "tile 滤镜失败：" + "x".repeat(5000);
         runner.thumbnail = new TranscodeRunner.ProducedThumbnail(
                 "transcoded/88/thumbnails/thumbnails.vtt",
                 "transcoded/88/thumbnails/sprite_",
                 1, 10, 1, 160, 0, 120, 120, 0L,
-                MediaThumbnail.STATUS_FAILED, "tile 滤镜失败");
+                MediaThumbnail.STATUS_FAILED, thumbnailError);
 
         worker.processOne();
 
@@ -128,6 +131,8 @@ class TranscodeWorkerTest {
         assertThat(thumbnail.getValue().getStatus())
                 .isEqualTo(MediaThumbnail.STATUS_FAILED);
         assertThat(thumbnail.getValue().getErrorMsg()).contains("tile");
+        assertThat(thumbnail.getValue().getErrorMsg()).contains("truncated");
+        assertThat(thumbnail.getValue().getErrorMsg().length()).isLessThanOrEqualTo(500);
         verify(mediaService).markReady(eq(ASSET_ID), anyString(), anyString(), eq(120));
         verify(transcodeService, never()).fail(any(), anyString());
     }
@@ -190,12 +195,16 @@ class TranscodeWorkerTest {
         private TranscodeRequest request;
         private RuntimeException failure;
         private ProducedThumbnail thumbnail;
+        private Integer progress;
         private boolean called;
 
         @Override
         public TranscodeResult run(TranscodeRequest request) {
             this.request = request;
             this.called = true;
+            if (progress != null) {
+                request.progressListener().accept(progress);
+            }
             if (failure != null) {
                 throw failure;
             }
diff --git a/sql/patch-2026-10-22-transcode-error-msg.sql b/sql/patch-2026-10-22-transcode-error-msg.sql
new file mode 100644
index 0000000..5b6319e
--- /dev/null
+++ b/sql/patch-2026-10-22-transcode-error-msg.sql
@@ -0,0 +1,12 @@
+-- Author: fruit.com.cn
+-- 扩展转码错误信息列，允许保留 ffmpeg / ffprobe 关键错误上下文（可重复执行）
+
+BEGIN;
+
+ALTER TABLE IF EXISTS transcode_task
+  ALTER COLUMN error_msg TYPE TEXT USING error_msg::TEXT;
+
+ALTER TABLE IF EXISTS media_thumbnail
+  ALTER COLUMN error_msg TYPE TEXT USING error_msg::TEXT;
+
+COMMIT;