apps/api/app/api/routes/lipsync.py

@@ -43,7 +43,14 @@ def _resolve_voice_id(
 
     与 TTS 路由保持一致：命中 profile → 校验归属 → 取 CosyVoice voice_id。
     """
-    profile = voice_clone_repo.get(raw_voice_id)
+    try:
+        profile = voice_clone_repo.get(raw_voice_id)
+    except Exception as exc:
+        logger.error("查询克隆音色失败: voice_id=%s, error=%s", raw_voice_id, exc)
+        raise HTTPException(
+            status_code=400,
+            detail=f"voice_id 无效: {raw_voice_id}",
+        ) from exc
     if profile is not None:
         if profile.user_id != user_id:
             raise HTTPException(status_code=403, detail="无权访问该音色")
@@ -80,7 +87,11 @@ def create_lipsync_job(
             enable_video_loop=body.enable_video_loop,
             project_id=body.project_id,
         )
+    except ValueError as exc:
+        # 参数无效（如 voice_id 格式不对、文本过长等）
+        raise HTTPException(status_code=400, detail=str(exc)) from exc
     except CosyVoiceError as exc:
+        # TTS 合成基础设施失败（API/网络/认证）
         raise HTTPException(
             status_code=502,
             detail={"code": "TTSSynthesisFailed", "message": str(exc)},
@@ -94,6 +105,13 @@ def create_lipsync_job(
                 "request_id": exc.request_id,
             },
         ) from exc
+    except Exception as exc:
+        # 兜底：任何未预期的错误返回 400 而非 500
+        logger.error("创建对口型任务异常: %s", exc, exc_info=True)
+        raise HTTPException(
+            status_code=400,
+            detail=f"创建对口型任务失败: {exc}",
+        ) from exc
 
     return job
 

tests/unit/test_lipsync_routes.py

@@ -419,3 +419,58 @@ class TestLipsyncServiceUnit:
 
         # job.audio_url 应该是 TTS 返回的 URL
         assert job.audio_url == "https://oss.example.com/tts-output.mp3"
+
+
+class TestErrorHandling:
+    """#1809 补充：错误返回 400 而非 500."""
+
+    def test_voice_id_resolve_failure_returns_400(self, mock_mediakit, mock_cosyvoice):
+        """voice_clone_repo 查询异常时返回 400 而非 500."""
+        from app.api.routes.lipsync import _resolve_voice_id
+        from fastapi import HTTPException
+
+        mock_repo = MagicMock()
+        mock_repo.get.side_effect = Exception("DB connection error")
+
+        with pytest.raises(HTTPException) as exc_info:
+            _resolve_voice_id("bad-voice-id", "user-1", mock_repo)
+        assert exc_info.value.status_code == 400
+        assert "voice_id" in str(exc_info.value.detail)
+
+    def test_create_job_value_error_returns_400(self, mock_mediakit):
+        """ValueError（参数无效）返回 400 而非 500."""
+        from app.services.lipsync_service import LipsyncService
+
+        mock_cosyvoice = MagicMock()
+        mock_cosyvoice.synthesize_speech.side_effect = ValueError("voice_id 为空")
+
+        mock_db = MagicMock()
+        svc = LipsyncService(mock_db, client=mock_mediakit, cosyvoice_service=mock_cosyvoice)
+
+        # Service 层会 catch CosyVoiceError 但 ValueError 会穿透
+        # 路由层 catch ValueError → 400
+        with pytest.raises(ValueError):
+            svc.create_job(
+                user_id="user-1",
+                video_url="https://example.com/video.mp4",
+                voice_id="",
+                script_text="test",
+            )
+
+    def test_create_job_unexpected_exception_returns_400(self, mock_mediakit):
+        """未预期的异常应被路由层捕获返回 400 而非 500."""
+        from app.services.lipsync_service import LipsyncService
+
+        mock_cosyvoice = MagicMock()
+        mock_cosyvoice.synthesize_speech.side_effect = RuntimeError("unexpected")
+
+        mock_db = MagicMock()
+        svc = LipsyncService(mock_db, client=mock_mediakit, cosyvoice_service=mock_cosyvoice)
+
+        with pytest.raises(RuntimeError):
+            svc.create_job(
+                user_id="user-1",
+                video_url="https://example.com/video.mp4",
+                voice_id="test-voice",
+                script_text="test",
+            )