pi-smart-router 0.16.2 → 0.17.0

package/.pi/extensions/smart-router/route-and-delegate.ts

@@ -52,6 +52,11 @@ function isPipedResult(
   return 'heldTerminal' in result;
 }
 
+/** Fail-open reason codes (SP-226) — emitted in telemetry and SMART_ROUTER_LOG_ROUTING=1. */
+export const NO_REGISTRY_MODEL = 'no_registry_model';
+export const FAILOVER_EXHAUSTED = 'failover_exhausted';
+export const DELEGATION_ABORTED = 'delegation_aborted';
+
 function isRoutingLogEnabled(): boolean {
   return process.env.SMART_ROUTER_LOG_ROUTING === '1';
 }
@@ -152,6 +157,68 @@ function isZeroOutputLengthStop(message: AssistantMessage): boolean {
   return message.stopReason === 'length' && message.usage.output === 0;
 }
 
+/** Minimal model identity for degraded terminal messages when no Model resolved. */
+interface DegradedModelRef {
+  readonly api: Api;
+  readonly provider: string;
+  readonly id: string;
+}
+
+function createDegradedErrorMessage(
+  model: DegradedModelRef,
+  reasonCode: string,
+  detail: string,
+): AssistantMessage {
+  return {
+    role: 'assistant',
+    content: [],
+    api: model.api,
+    provider: model.provider,
+    model: model.id,
+    usage: {
+      input: 0,
+      output: 0,
+      cacheRead: 0,
+      cacheWrite: 0,
+      totalTokens: 0,
+      cost: { input: 0, output: 0, cacheRead: 0, cacheWrite: 0, total: 0 },
+    },
+    stopReason: 'error',
+    errorMessage: `Smart router degraded response (${reasonCode}): ${detail}`,
+    timestamp: Date.now(),
+  };
+}
+
+/**
+ * Fail-open terminal (SP-226): never throw to the host on exhaustion paths.
+ * Emit a structured warning with the reason code and end the outer stream with
+ * a degraded error message so the pi host receives an actionable response.
+ */
+function emitDegradedFailure(
+  outer: AssistantMessageEventStream,
+  model: DegradedModelRef | undefined,
+  selectedModelId: string,
+  reasonCode: string,
+  detail: string,
+): void {
+  console.warn(
+    '[smart-router] fail-open degraded response',
+    JSON.stringify({
+      reason_code: reasonCode,
+      selected_model_id: selectedModelId,
+      detail,
+    }),
+  );
+  const ref: DegradedModelRef = model ?? {
+    api: 'unknown',
+    provider: 'unknown',
+    id: selectedModelId,
+  };
+  const errorMessage = createDegradedErrorMessage(ref, reasonCode, detail);
+  outer.push({ type: 'error', reason: 'error', error: errorMessage });
+  outer.end(errorMessage);
+}
+
 function buildOverflowRoutingDecision(
   base: RoutingDecision,
   fallback: ReturnType<typeof resolveContextOverflowFallback>,
@@ -357,9 +424,18 @@ export async function routeAndDelegate(
     if (decision.selected_model_id === 'unknown' && guardResult) {
       assertRoutableFleetAfterGeminiToolHistoryGuard(guardResult);
     }
-    throw new Error(
+    // SP-226 fail-open: no registry model resolved — degrade instead of throwing.
+    deps.router.dispatch.recordOutcome(decision.selected_model_id, {
+      code: 'NO_REGISTRY_MODEL',
+    });
+    emitDegradedFailure(
+      outer,
+      undefined,
+      decision.selected_model_id,
+      NO_REGISTRY_MODEL,
       `No registry model available for routing decision ${decision.selected_model_id}`,
     );
+    return;
   }
 
   logRoutingDecision(decision, {
@@ -546,6 +622,16 @@ export async function routeAndDelegate(
       return;
     } catch (error) {
       if (isAbortError(error, options)) {
+        // SP-226: telemetry for phase-boundary aborts (previously silent).
+        if (isRoutingLogEnabled()) {
+          console.warn(
+            '[smart-router] delegation aborted',
+            JSON.stringify({
+              reason_code: DELEGATION_ABORTED,
+              model_id: targetModel.id,
+            }),
+          );
+        }
         const abortMessage = createErrorMessage(targetModel, options, error);
         outer.push({ type: 'error', reason: 'aborted', error: abortMessage });
         outer.end(abortMessage);
@@ -565,7 +651,7 @@ export async function routeAndDelegate(
       );
       const alternateModel = failover ? resolveTargetModel(deps, failover) : undefined;
 
-      if (alternateModel && alternateModel.id !== targetModel.id) {
+      if (failover && alternateModel && alternateModel.id !== targetModel.id) {
         console.warn(
           '[smart-router] stream delegation failed, failing over',
           error instanceof Error ? error.message : String(error),
@@ -575,9 +661,6 @@ export async function routeAndDelegate(
           alternateModelId: alternateModel.id,
           errorObj: { message: error instanceof Error ? error.message : String(error) },
         };
-        if (!failover) {
-          throw error;
-        }
         decision = failover;
         targetModel = alternateModel;
         continue;
@@ -585,7 +668,16 @@ export async function routeAndDelegate(
 
       const fallbackModel = resolveFallbackModel(deps, effectiveFleet);
       if (!fallbackModel || fallbackModel.id === targetModel.id) {
-        throw error;
+        // SP-226 fail-open: fleet/failover exhausted and no distinct safe
+        // default — degrade instead of throwing to the host.
+        emitDegradedFailure(
+          outer,
+          targetModel,
+          decision.selected_model_id,
+          FAILOVER_EXHAUSTED,
+          error instanceof Error ? error.message : String(error),
+        );
+        return;
       }
 
       console.warn(

package/.pi/extensions/smart-router/routing-context.ts

@@ -76,6 +76,35 @@ function messageContentToString(content: string | readonly (TextContent | { type
     .join('\n');
 }
 
+/**
+ * SP-225 / #137: read an HTTP-ish status a host may attach to a tool result
+ * (either directly on the message or inside `details`). Returns undefined
+ * when no finite numeric status is present.
+ */
+function readOptionalStatus(source: unknown): number | undefined {
+  if (source === null || typeof source !== 'object') {
+    return undefined;
+  }
+  const record = source as Record<string, unknown>;
+  const direct = record.status;
+  if (typeof direct === 'number' && Number.isFinite(direct) && direct >= 0) {
+    return Math.floor(direct);
+  }
+  return readOptionalStatus(record.details);
+}
+
+export interface MapContextMessagesOptions {
+  /**
+   * Opt-in: include assistant `thinking` blocks in routing `content`.
+   * Default false — thinking is model-internal reasoning, not a routing
+   * signal, and leaking it inflates token estimates (#137).
+   */
+  includeThinking?: boolean;
+}
+
+/** Operator env gate restoring the pre-SP-225 thinking-in-content behavior. */
+const INCLUDE_THINKING_ENV = 'SMART_ROUTER_INCLUDE_THINKING';
+
 export function extractPromptText(messages: readonly Message[]): string {
   for (let i = messages.length - 1; i >= 0; i--) {
     const message = messages[i];
@@ -117,7 +146,11 @@ export function deriveTurnType(messages: readonly Message[]): TurnType {
   return 'main_loop';
 }
 
-export function mapContextMessages(messages: readonly Message[]): RoutingMessage[] {
+export function mapContextMessages(
+  messages: readonly Message[],
+  options?: MapContextMessagesOptions,
+): RoutingMessage[] {
+  const includeThinking = options?.includeThinking === true;
   return messages.map((message) => {
     if (message.role === 'user') {
       return {
@@ -127,27 +160,53 @@ export function mapContextMessages(messages: readonly Message[]): RoutingMessage
     }
 
     if (message.role === 'assistant') {
-      const content = message.content
-        .map((block) => {
-          if (block.type === 'text') {
-            return block.text;
+      const contentParts: string[] = [];
+      const toolBlocks: Record<string, unknown>[] = [];
+      for (const block of message.content) {
+        if (block.type === 'text') {
+          contentParts.push(block.text);
+        } else if (block.type === 'thinking') {
+          if (includeThinking) {
+            contentParts.push(block.thinking);
           }
-          if (block.type === 'thinking') {
-            return block.thinking;
-          }
-          return '';
-        })
-        .filter(Boolean)
-        .join('\n');
+        } else if (block.type === 'toolCall') {
+          toolBlocks.push({
+            type: 'tool_call',
+            tool_call_id: block.id,
+            tool_name: block.name,
+          });
+        }
+      }
 
-      return { role: message.role, content };
+      const mapped: RoutingMessage = {
+        role: message.role,
+        content: contentParts.filter(Boolean).join('\n'),
+      };
+      if (toolBlocks.length > 0) {
+        return { ...mapped, tool_blocks: toolBlocks };
+      }
+      return mapped;
     }
 
+    const status = readOptionalStatus(message);
+    // When a host attaches an HTTP-ish status, let the domain status>=400 rule
+    // arbitrate (#137): a bare isError=false would otherwise mask the
+    // structured signal. Without a status, preserve the host isError verbatim.
+    const isError = message.isError === true || status === undefined
+      ? message.isError
+      : undefined;
     return {
       role: 'tool',
       content: messageContentToString(message.content),
-      tool_blocks: [],
-      is_error: message.isError,
+      tool_blocks: [
+        {
+          type: 'tool_result',
+          tool_call_id: message.toolCallId,
+          tool_name: message.toolName,
+        },
+      ],
+      ...(isError !== undefined ? { is_error: isError } : {}),
+      ...(status !== undefined ? { status } : {}),
     };
   });
 }
@@ -164,7 +223,9 @@ export function buildRoutingRequest(
     request_id: randomUUID(),
     session_id: sessionId,
     prompt_text: extractPromptText(context.messages),
-    messages: mapContextMessages(context.messages),
+    messages: mapContextMessages(context.messages, {
+      includeThinking: process.env[INCLUDE_THINKING_ENV] === '1',
+    }),
     turn_type: deriveTurnType(context.messages),
     estimated_input_tokens: estimateInputTokens(context, options),
     ...lifecycleFlags,

package/README.md

@@ -2,7 +2,7 @@
 
 **Auto-model router middleware for the [pi](https://pi.dev) coding agent.**
 
-> **v0.1.0** is initial development (SemVer `0.y.z`). The public API and routing behavior may change until `1.0.0`.
+> Current release: **v0.16.2** (mirrors `package.json`; SemVer `0.y.z`). The public API and routing behavior may change until `1.0.0`.
 
 pi-smart-router intercepts every LLM inference request and dynamically routes it to the optimal execution engine — balancing cost, capability, latency, and time-to-first-token (TTFT) — without requiring you to manually pick a model for each turn.
 
@@ -18,8 +18,8 @@ pi-smart-router intercepts every LLM inference request and dynamically routes it
 ```text
 request → hardware probe → loop escalation → turn envelope → context-fit gate
         → low-intensity tier gate → session pin → deterministic triage
-        → local zero-tier → HyDRA embedding matcher → safe cloud default
-        → context overflow fallback
+        → local zero-tier → triage cloud fallback → HyDRA embedding matcher
+        → safe cloud default → context overflow fallback
 ```
 
 The pipeline runs **12 stages sequentially with early exit** — the moment any stage reaches a routing decision, subsequent stages are skipped. Every decision includes the stage name, reason code, candidates considered, estimated cost, and routing latency for full observability.
@@ -34,6 +34,7 @@ The pipeline runs **12 stages sequentially with early exit** — the moment any
 | Session Pin | <1ms | Returns pinned model if session has one; breaks pin on compaction or overflow |
 | Deterministic Triage | <5ms | Aho-Corasick keyword scan + cyclomatic complexity analysis |
 | Local Zero-Tier | <15ms | Pings LM Studio + Ollama in parallel; routes locally when eligible |
+| Triage Cloud Fallback | <2ms | Trivial prompts not claimed locally route to the first healthy economical-cloud model |
 | HyDRA Matcher | 80-120ms | ONNX embeddings, 3D requirement projection, shortfall gate, multi-objective scoring |
 | Safe Cloud Default | — | First healthy economical-cloud model (context-fit aware) |
 | Context Overflow Fallback | — | Escalates to largest-fit model when economical tiers cannot fit |
@@ -258,6 +259,10 @@ After typing `/smart-router ` (with a trailing space), press **TAB** to see subc
 npm run verify:ci
 ```
 
+## Concurrency contract
+
+`RouterPipeline.route()` calls on a single router instance are **single-flight**: concurrent calls are serialized internally (SP-230, [#141](https://github.com/beettlle/pi-smart-router/issues/141)). The pipeline keeps per-route transient state on instance fields while stages run, so overlapping executions are queued rather than interleaved — each queued call waits at most one routing latency. This applies to `createRouter()` / `createRouterFromFleet()` handles: a shared `router.dispatch` is safe to call concurrently, and serialization does not change routing policy outcomes. For parallel routing throughput, create separate router instances.
+
 ## Fleet behavior
 
 When you use `smart-router/auto`, the extension does **not** read `config/models.yaml`. Instead:
@@ -949,7 +954,7 @@ Contributors must run `npm run build` before publishing or consuming the library
 | `npm run release:check` | Pre-release gate: `verify:ci` + consumer pack + Tier 0 functional smoke |
 | `npm run release:functional-smoke` | Tier 0 functional smoke: calibration verify (`--skip-embed`), benchmark profiles, release gate assertions |
 | `npm run release:consumer-pack` | Pack tarball and verify production dependencies resolve (catches missing runtime deps) |
-| `npm run verify:ci` | Full CI parity: build, typecheck, lint, test, coverage |
+| `npm run verify:ci` | Full CI parity: build, typecheck, lint, test, coverage (baseline PR gate; see [PR and pre-release quality gate set](#pr-and-pre-release-quality-gate-set)) |
 | `npm run typecheck` | TypeScript strict mode check (`tsc --noEmit`) |
 | `npm test` | Run test suite (`vitest run`) |
 | `npm run coverage:check` | Tests with line-coverage thresholds |
@@ -1008,7 +1013,9 @@ npm run routing:eval-replay
 npm run routing:twinrouterbench:full-track
 ```
 
-**CI smoke:** `.github/workflows/eval-harness-smoke.yml` runs on PRs that touch eval scripts, fixtures, or the workflow. It executes `routing:eval-harness:smoke`, `routing:eval-harness:corpus-smoke`, and eval unit tests — fast, offline, no provider network calls. Job timeout stays at 10 minutes. The optional full-track nightly (`.github/workflows/twinrouterbench-full-nightly.yml`, `schedule` + `workflow_dispatch` only) is **not** on `pull_request` and must not be configured as a required status check — failures there do not gate PR CI or `release:functional-smoke`.
+**CI smoke:** `.github/workflows/eval-harness-smoke.yml` runs on PRs that touch eval scripts, fixtures, **any `src/**` or `.pi/extensions/smart-router/**` change**, or the workflow. It executes `routing:eval-harness:smoke`, `routing:eval-harness:corpus-smoke`, and eval unit tests — fast, offline, no provider network calls. Job timeout stays at 10 minutes. The optional full-track nightly (`.github/workflows/twinrouterbench-full-nightly.yml`, `schedule` + `workflow_dispatch` only) is **not** on `pull_request` and must not be configured as a required status check — failures there do not gate PR CI or `release:functional-smoke`.
+
+**Calibration verify:** `.github/workflows/calibration-verify.yml` runs on PRs that touch calibration config/scripts (`config/routing-calibration.json*`, `config/p-success-weights.json`, `scripts/train-routing-calibration.ts`, `scripts/verify-routing-calibration.ts`, `scripts/lib/isotonic-calibrator.ts`, `scripts/lib/oats-centroid-refinement.ts`) **or calibration-consuming routing code** (`src/domain/routing/**`, `src/domain/pipeline/**`, `src/domain/types/**`, `src/cli/**`). It builds the library and verifies `config/routing-calibration.json.example` against benchmark prompts via `npm run routing:verify-calibration`.
 
 **TwinRouterBench static track:** import step-level router-visible prefixes with execution-verified target tiers (`track: "static"`). The adapter in `scripts/eval/twinrouterbench-adapter.ts` converts static track records into native eval fixtures for the three-track harness. See `docs/gemini-research.md` §9 for methodology context.
 
@@ -1178,6 +1185,21 @@ npm run routing:verify-benchmark-profiles
 
 Tag-triggered publish via GitHub Actions (requires `NPMSECRET` repository secret). pi.dev gallery listing syncs automatically from npm (`pi-package` keyword); no separate submit step.
 
+#### PR and pre-release quality gate set
+
+Operators should treat the following as the full gate set before merging routing changes and before tagging a release ([#135](https://github.com/beettlle/pi-smart-router/issues/135)):
+
+| Gate | Workflow / command | Runs when |
+|------|--------------------|-----------|
+| Build / typecheck / lint / coverage | `.github/workflows/ci.yml` (`npm run verify:ci`) | Every PR and push to `main` |
+| Eval harness smoke (offline) | `.github/workflows/eval-harness-smoke.yml` | PRs touching `scripts/eval/**`, `tests/eval/**`, **`src/**`**, **`.pi/extensions/smart-router/**`**, `package.json`, or the workflow |
+| Calibration verify | `.github/workflows/calibration-verify.yml` | PRs touching calibration config/scripts or calibration-consuming routing code (`src/domain/routing/**`, `src/domain/pipeline/**`, `src/domain/types/**`, `src/cli/**`) |
+| Benchmark profile smoke | `.github/workflows/benchmark-profile-refresh.yml` (`routing:verify-benchmark-profiles`) | PRs touching fixtures / ingest / profiles |
+| Pre-release functional smoke | `npm run release:check` (Tier 0: calibration `--skip-embed` + benchmark profiles + release-gate assertions) | Operator-run before `npm version` / tag |
+| TwinRouterBench full track | `.github/workflows/twinrouterbench-full-nightly.yml` | Nightly / manual only — **never** a required PR check |
+
+Required-check configuration for branch protection is a human-operator repo-settings decision; the workflow path filters above guarantee the jobs **run** on routing code edits regardless of which subset the operator marks required.
+
 **Scope composition:** use `/skill:router-release-operator` for themed release planning (not open-ended backlog cycles). **Patch** = docs + bugfixes only; **minor** = new capability (1–3 related issues under one theme). Budgets and audit rules: [`skills/router-release-operator/references/release-profiles.md`](skills/router-release-operator/references/release-profiles.md).
 
 **Tier 0 functional smoke** (`release:functional-smoke`) runs before tag publish and chains:

package/config/benchmark-profiles.json

@@ -7,8 +7,8 @@
       "livecodebench": "https://livecodebench.github.io/leaderboard.html",
       "bfcl": "https://gorilla.cs.berkeley.edu/leaderboard.html"
     },
-    "scrape_date": "2026-08-20",
-    "catalog_freeze_date": "2026-08-20"
+    "scrape_date": "2026-08-22",
+    "catalog_freeze_date": "2026-08-22"
   },
   "aliases": {
     "anthropic/claude-opus-4": "claude-opus-4-5",

package/config/operator-config.json.example

@@ -58,6 +58,12 @@
       "max_messages": 12,
       "max_tokens": 16384,
       "exclude_execution_history": true
+    },
+    "global_timeout_ms": 120000,
+    "sub_call_timeout_ms": 30000,
+    "_timeouts_documentation": {
+      "global_timeout_ms": "Global cap (ms) for the whole delegate stage; mirrors llm-use WORKER_GLOBAL_TIMEOUT. Default 120000 (SP-213, #120).",
+      "sub_call_timeout_ms": "Per-call cap (ms) for each delegate sub-call worker; mirrors llm-use WORKER_CALL_TIMEOUT. Default 30000 (SP-213, #120)."
     }
   },
   "local_zero": {

package/dist/domain/pipeline/router-pipeline.d.ts

@@ -143,8 +143,34 @@ export declare class RouterPipeline {
     private currentPrewarmOutcome;
     /** Lazily created session-scoped prewarm guard (acceptance state spans routes). */
     private prewarmGuardInstance;
+    /**
+     * Single-flight serialization tail (SP-230, #141).
+     *
+     * Concurrency contract: `route()` calls on one RouterPipeline instance are
+     * serialized — a concurrent caller queues behind the in-flight call. The
+     * pipeline keeps per-route transient state on instance fields (the
+     * `current*` / `activeFleet` / `fullFleet` members above), which every stage
+     * reads and writes; overlapping route() executions would race on that state
+     * and corrupt routing decisions (e.g. a second call's reset swapping
+     * `activeFleet` mid-flight for the first). Routing is a fast, bounded,
+     * in-memory computation, so serialization costs at most one routing latency
+     * of queuing and never changes routing policy outcomes.
+     *
+     * Safety notes:
+     * - No reentrancy: nothing on a route() execution path awaits another
+     *   route()/dispatch() on the same instance, so the chain cannot deadlock.
+     * - The tail is chained with a rejection handler so a rejected call (the
+     *   zero-crash catch makes this defensive-only) cannot wedge the queue.
+     */
+    private routeTail;
     constructor(fleet: readonly ModelProfile[], options?: PipelineOptions);
+    /**
+     * Route a request through the pipeline. Concurrent calls are serialized
+     * (single-flight) — see `routeTail` for the concurrency contract (SP-230).
+     */
     route(request: RoutingRequest, fleetOverride?: readonly ModelProfile[]): Promise<RoutingDecision>;
+    /** Exclusive-route body — never invoke concurrently; see `route()` (SP-230). */
+    private routeExclusive;
     /**
      * SP-080: move Google/Gemini profiles to the end of the fleet when prior tool
      * calls exist so tier `.find()` passes prefer non-Gemini models first.

package/dist/domain/pipeline/router-pipeline.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"router-pipeline.d.ts","sourceRoot":"","sources":["../../../src/domain/pipeline/router-pipeline.ts"],"names":[],"mappings":"AAAA;;;;;;;;;GASG;AAEH,OAAO,KAAK,EACV,YAAY,EACZ,sBAAsB,EAEtB,YAAY,EAEZ,eAAe,EAEf,cAAc,EACd,UAAU,EACV,IAAI,EAEL,MAAM,mBAAmB,CAAC;AAC3B,OAAO,KAAK,EAAE,mBAAmB,EAAE,MAAM,sBAAsB,CAAC;AAChE,OAAO,KAAK,EAAE,kBAAkB,EAAE,eAAe,EAAE,mBAAmB,EAAE,MAAM,qBAAqB,CAAC;AAEpG,OAAO,KAAK,EAAE,mBAAmB,EAAuB,UAAU,EAAE,MAAM,iDAAiD,CAAC;AAC5H,OAAO,KAAK,EAAE,eAAe,EAAE,MAAM,mDAAmD,CAAC;AACzF,OAAO,KAAK,EAAE,aAAa,EAAwB,mBAAmB,EAAE,MAAM,+CAA+C,CAAC;AAI9H,OAAO,KAAK,EAAgB,aAAa,EAAE,MAAM,4BAA4B,CAAC;AAO9E,OAAO,EAKL,KAAK,gBAAgB,EACtB,MAAM,2BAA2B,CAAC;AACnC,OAAO,KAAK,EAAE,aAAa,EAAE,MAAM,8BAA8B,CAAC;AAQlE,OAAO,KAAK,EAAE,oBAAoB,EAAE,MAAM,+BAA+B,CAAC;AAE1E,OAAO,EACL,uBAAuB,EAWxB,MAAM,qDAAqD,CAAC;AAC7D,OAAO,KAAK,EAAE,YAAY,IAAI,gBAAgB,EAAe,MAAM,8BAA8B,CAAC;AAClG,OAAO,KAAK,EAAE,cAAc,EAAE,kBAAkB,EAAE,MAAM,gCAAgC,CAAC;AAGzF,OAAO,EAGL,KAAK,mBAAmB,EACxB,KAAK,mBAAmB,EACxB,KAAK,iBAAiB,EAEvB,MAAM,uCAAuC,CAAC;AAM/C,OAAO,EAGL,KAAK,0BAA0B,EAChC,MAAM,mCAAmC,CAAC;AAC3C,OAAO,EAIL,KAAK,eAAe,EACrB,MAAM,oCAAoC,CAAC;AAK5C,OAAO,EAGL,uBAAuB,EAEvB,KAAK,wBAAwB,EAC9B,MAAM,mCAAmC,CAAC;AAI3C,MAAM,WAAW,WAAW;IAC1B,QAAQ,CAAC,OAAO,EAAE,OAAO,CAAC;IAC1B,QAAQ,CAAC,QAAQ,CAAC,EAAE,eAAe,CAAC;IACpC,QAAQ,CAAC,KAAK,EAAE,MAAM,CAAC;CACxB;AAED,MAAM,MAAM,aAAa,GAAG,CAAC,OAAO,EAAE,cAAc,KAAK,OAAO,CAAC,WAAW,CAAC,CAAC;AAE9E,2EAA2E;AAC3E,eAAO,MAAM,oBAAoB,6NAavB,CAAC;AAEX,MAAM,MAAM,iBAAiB,GAAG,CAAC,OAAO,oBAAoB,CAAC,CAAC,MAAM,CAAC,CAAC;AAOtE,kFAAkF;AAClF,MAAM,WAAW,kBAAkB;IACjC,QAAQ,CAAC,aAAa,EAAE,aAAa,GAAG,IAAI,CAAC;IAC7C,QAAQ,CAAC,QAAQ,EAAE,IAAI,GAAG,IAAI,CAAC;IAC/B,QAAQ,CAAC,iBAAiB,EAAE,MAAM,GAAG,IAAI,CAAC;IAC1C,QAAQ,CAAC,aAAa,EAAE,MAAM,CAAC;IAC/B,QAAQ,CAAC,YAAY,EAAE,kBAAkB,GAAG,IAAI,CAAC;CAClD;AAED,MAAM,WAAW,mBAAmB;IAClC,QAAQ,CAAC,QAAQ,EAAE,OAAO,CAAC;IAC3B,QAAQ,CAAC,MAAM,EAAE,MAAM,GAAG,IAAI,CAAC;CAChC;AAED;;;GAGG;AACH,wBAAgB,oBAAoB,CAAC,KAAK,EAAE,kBAAkB,GAAG,mBAAmB,CAsCnF;AAgBD,wBAAgB,+BAA+B,CAAC,UAAU,EAAE,MAAM,GAAG,MAAM,CAgB1E;AAED,wBAAgB,8BAA8B,CAC5C,sBAAsB,EAAE,MAAM,EAC9B,qBAAqB,EAAE,MAAM,GAC5B,MAAM,CAER;AAID,MAAM,WAAW,eAAe;IAC9B,QAAQ,CAAC,cAAc,CAAC,EAAE,mBAAmB,CAAC;IAC9C,QAAQ,CAAC,WAAW,CAAC,EAAE,mBAAmB,CAAC;IAC3C,QAAQ,CAAC,kBAAkB,CAAC,EAAE,MAAM,OAAO,CAAC,UAAU,CAAC,CAAC;IACxD,QAAQ,CAAC,aAAa,CAAC,EAAE,aAAa,CAAC;IACvC,QAAQ,CAAC,aAAa,CAAC,EAAE,aAAa,CAAC;IACvC,QAAQ,CAAC,oBAAoB,CAAC,EAAE,oBAAoB,CAAC;IACrD,QAAQ,CAAC,gBAAgB,CAAC,EAAE,uBAAuB,CAAC;IACpD,QAAQ,CAAC,YAAY,CAAC,EAAE,gBAAgB,CAAC;IACzC,QAAQ,CAAC,cAAc,CAAC,EAAE,cAAc,CAAC;IACzC,QAAQ,CAAC,kBAAkB,CAAC,EAAE,kBAAkB,CAAC;IACjD,QAAQ,CAAC,YAAY,CAAC,EAAE,YAAY,GAAG,IAAI,CAAC;IAC5C,QAAQ,CAAC,gBAAgB,CAAC,EAAE,gBAAgB,CAAC;IAC7C,yFAAyF;IACzF,QAAQ,CAAC,eAAe,CAAC,EAAE,eAAe,CAAC;IAC3C,QAAQ,CAAC,mBAAmB,CAAC,EAAE,MAAM,CAAC;IACtC,wFAAwF;IACxF,QAAQ,CAAC,kBAAkB,CAAC,EAAE,0BAA0B,GAAG,IAAI,CAAC;IAChE,QAAQ,CAAC,sBAAsB,CAAC,EAAE,MAAM,CAAC;IACzC,kFAAkF;IAClF,QAAQ,CAAC,UAAU,CAAC,EAAE,UAAU,CAAC;IACjC,mFAAmF;IACnF,QAAQ,CAAC,sBAAsB,CAAC,EAAE,sBAAsB,CAAC;IACzD,wEAAwE;IACxE,QAAQ,CAAC,mBAAmB,CAAC,EAAE,mBAAmB,CAAC;IACnD,+CAA+C;IAC/C,QAAQ,CAAC,mBAAmB,CAAC,EAAE,mBAAmB,CAAC;IACnD;;;OAGG;IACH,QAAQ,CAAC,eAAe,CAAC,EAAE,OAAO,CAAC;IACnC,uEAAuE;IACvE,QAAQ,CAAC,eAAe,CAAC,EAAE,eAAe,CAAC;IAC3C,6DAA6D;IAC7D,QAAQ,CAAC,eAAe,CAAC,EAAE,eAAe,CAAC;IAC3C,8DAA8D;IAC9D,QAAQ,CAAC,mBAAmB,CAAC,EAAE,mBAAmB,CAAC;IACnD,wEAAwE;IACxE,QAAQ,CAAC,aAAa,CAAC,EAAE,wBAAwB,CAAC;IAClD,wFAAwF;IACxF,QAAQ,CAAC,YAAY,CAAC,EAAE,uBAAuB,CAAC;IAChD,yEAAyE;IACzE,QAAQ,CAAC,iBAAiB,CAAC,EAAE,iBAAiB,CAAC;IAC/C,uFAAuF;IACvF,QAAQ,CAAC,WAAW,CAAC,EAAE,mBAAmB,CAAC;CAC5C;AAID,qBAAa,cAAc;IACzB,OAAO,CAAC,QAAQ,CAAC,MAAM,CAAgC;IACvD,OAAO,CAAC,QAAQ,CAAC,KAAK,CAA0B;IAChD,OAAO,CAAC,QAAQ,CAAC,OAAO,CAAkB;IAE1C,iEAAiE;IACjE,OAAO,CAAC,WAAW,CAA+B;IAElD,yDAAyD;IACzD,OAAO,CAAC,SAAS,CAA+B;IAEhD,8DAA8D;IAC9D,OAAO,CAAC,qBAAqB,CAAmC;IAChE,OAAO,CAAC,mBAAmB,CAA6B;IACxD,OAAO,CAAC,kBAAkB,CAA4B;IACtD,OAAO,CAAC,mBAAmB,CAAmC;IAC9D,OAAO,CAAC,eAAe,CAAqB;IAC5C,OAAO,CAAC,yBAAyB,CAAuB;IACxD,OAAO,CAAC,wBAAwB,CAAuB;IACvD,OAAO,CAAC,oBAAoB,CAAuB;IACnD,OAAO,CAAC,kBAAkB,CAAuB;IACjD,OAAO,CAAC,yBAAyB,CAAuB;IACxD,OAAO,CAAC,oBAAoB,CAAuB;IACnD,OAAO,CAAC,yBAAyB,CAAwC;IACzE,OAAO,CAAC,0BAA0B,CAAuB;IACzD,OAAO,CAAC,qBAAqB,CAAS;IACtC,OAAO,CAAC,qBAAqB,CAAgC;IAC7D,OAAO,CAAC,wBAAwB,CAAS;IACzC,OAAO,CAAC,wBAAwB,CAA2C;IAC3E,OAAO,CAAC,yBAAyB,CAAiC;IAClE,OAAO,CAAC,4BAA4B,CAAK;IACzC,OAAO,CAAC,gCAAgC,CAAuB;IAC/D,OAAO,CAAC,wBAAwB,CAAS;IACzC,gEAAgE;IAChE,OAAO,CAAC,sBAAsB,CAAuB;IACrD,2EAA2E;IAC3E,OAAO,CAAC,uBAAuB,CAA8C;IAC7E,mFAAmF;IACnF,OAAO,CAAC,+BAA+B,CAAyB;IAChE,yEAAyE;IACzE,OAAO,CAAC,gBAAgB,CAA0B;IAClD,OAAO,CAAC,0BAA0B,CAAuB;IACzD,wEAAwE;IACxE,OAAO,CAAC,qBAAqB,CAA+B;IAC5D,mFAAmF;IACnF,OAAO,CAAC,oBAAoB,CAAwC;IAEpE;;;;;;;;;;;;;;;;;;OAkBG;IACH,OAAO,CAAC,SAAS,CAAoC;gBAEzC,KAAK,EAAE,SAAS,YAAY,EAAE,EAAE,OAAO,CAAC,EAAE,eAAe;IAmBrE;;;OAGG;IACG,KAAK,CACT,OAAO,EAAE,cAAc,EACvB,aAAa,CAAC,EAAE,SAAS,YAAY,EAAE,GACtC,OAAO,CAAC,eAAe,CAAC;IAc3B,gFAAgF;YAClE,cAAc;IAgE5B;;;;OAIG;IACH,OAAO,CAAC,6BAA6B;IAmCrC,6FAA6F;IAC7F,OAAO,CAAC,cAAc;IAkDtB,yFAAyF;IACzF,OAAO,CAAC,8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package/dist/domain/pipeline/router-pipeline.js

@@ -157,6 +157,26 @@ export class RouterPipeline {
     currentPrewarmOutcome = null;
     /** Lazily created session-scoped prewarm guard (acceptance state spans routes). */
     prewarmGuardInstance = null;
+    /**
+     * Single-flight serialization tail (SP-230, #141).
+     *
+     * Concurrency contract: `route()` calls on one RouterPipeline instance are
+     * serialized — a concurrent caller queues behind the in-flight call. The
+     * pipeline keeps per-route transient state on instance fields (the
+     * `current*` / `activeFleet` / `fullFleet` members above), which every stage
+     * reads and writes; overlapping route() executions would race on that state
+     * and corrupt routing decisions (e.g. a second call's reset swapping
+     * `activeFleet` mid-flight for the first). Routing is a fast, bounded,
+     * in-memory computation, so serialization costs at most one routing latency
+     * of queuing and never changes routing policy outcomes.
+     *
+     * Safety notes:
+     * - No reentrancy: nothing on a route() execution path awaits another
+     *   route()/dispatch() on the same instance, so the chain cannot deadlock.
+     * - The tail is chained with a rejection handler so a rejected call (the
+     *   zero-crash catch makes this defensive-only) cannot wedge the queue.
+     */
+    routeTail = Promise.resolve();
     constructor(fleet, options) {
         this.fleet = fleet;
         this.options = options ?? {};
@@ -175,7 +195,20 @@ export class RouterPipeline {
             { name: 'context_overflow_fallback', run: this.contextOverflowFallback.bind(this) },
         ];
     }
+    /**
+     * Route a request through the pipeline. Concurrent calls are serialized
+     * (single-flight) — see `routeTail` for the concurrency contract (SP-230).
+     */
     async route(request, fleetOverride) {
+        const queued = this.routeTail.then(() => this.routeExclusive(request, fleetOverride));
+        // Keep the tail alive even if a call rejects (defensive: routeExclusive
+        // catches stage errors, but a throw outside that catch must not wedge the
+        // queue for subsequent callers).
+        this.routeTail = queued.then(() => undefined, () => undefined);
+        return queued;
+    }
+    /** Exclusive-route body — never invoke concurrently; see `route()` (SP-230). */
+    async routeExclusive(request, fleetOverride) {
         const start = Date.now();
         this.activeFleet = this.prioritizeFleetForToolHistory(fleetOverride ?? this.fleet, request);
         this.fullFleet = this.activeFleet;
@@ -1174,6 +1207,12 @@ export class RouterPipeline {
         };
     }
     logExpectedCostExplain(pSuccessCheap, alpha, selection, calibration) {
+        // SP-223 / #138: gate stdout explain behind SMART_ROUTER_LOG_ROUTING —
+        // the full payload is already captured in decision features/telemetry, so
+        // default runs must not flood stdout on every eligible route.
+        if (process.env.SMART_ROUTER_LOG_ROUTING !== '1') {
+            return;
+        }
         console.info('Expected-cost tier gate', {
             reason: selection.reasonCode,
             p_success_cheap: pSuccessCheap,