Update CodeQL workflow with timeout, fail-fast error handling, and rosdep resilience

[Copilot]

Changes

This PR improves the CodeQL CI workflow configuration to ensure more reliable and efficient execution:

1. Added Job Timeout

• Set timeout-minutes: 60 for the analyze job to prevent indefinite hangs
• The job will now fail gracefully after 1 hour if it hasn't completed, though healthy runs should finish well before this limit

2. Added Fail-Fast Error Handling

• Added set -e to all shell script steps (Prepare ROS, Install package dependencies, Build package)
• This ensures each step fails immediately on any command error rather than continuing silently
• Prevents workflows from hanging or producing misleading success status when errors occur

3. Improved rosdep Initialization

• Added || echo "rosdep already initialized" to the rosdep init step
• Prevents workflow failures in environments where rosdep is already initialized
• Makes the workflow more resilient to different execution contexts

Impact

These changes are workflow-only modifications with no impact on the codebase. The CodeQL job will now:

• Start and complete more reliably
• Fail early and clearly when errors occur
• Handle edge cases like pre-initialized rosdep gracefully
• Have a safety timeout to prevent resource waste

The runner version remains unchanged at ubuntu-20.04.

Original prompt

Update CI configuration to ensure CodeQL job starts and finishes efficiently. Set timeout-minutes to 60 for the analyze job. Add set -e to all shell script steps to fail fast on any error and prevent silent workflow hangs. Add || echo "rosdep already initialized" to the rosdep init step to avoid failures if rosdep is already initialized. Do not change the runner version. No codebase changes – only update the workflow file.

Refer to the workflow file: !.github/workflows/codeql-analysis.yml

The CodeQL job should now reliably start, fail early on errors, and have a timeout of 1 hour, but should typically finish well before that when the job is healthy.

This pull request was created as a result of the following prompt from Copilot chat.

Update CI configuration to ensure CodeQL job starts and finishes efficiently. Set timeout-minutes to 60 for the analyze job. Add set -e to all shell script steps to fail fast on any error and prevent silent workflow hangs. Add || echo "rosdep already initialized" to the rosdep init step to avoid failures if rosdep is already initialized. Do not change the runner version. No codebase changes – only update the workflow file.

Refer to the workflow file: !.github/workflows/codeql-analysis.yml

The CodeQL job should now reliably start, fail early on errors, and have a timeout of 1 hour, but should typically finish well before that when the job is healthy.

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