feat: add request queuing to router (replaces hard 503 on saturation)

When all GPUs are saturated, requests now enter a queue loop (poll every 500ms)
instead of immediately returning 503. Configurable via QUEUE_TIMEOUT env var
(default 30s) or X-Queue-Timeout header per-request.

This prevents agent failures from cluster saturation — agents wait for a slot
instead of crashing on fallback.

router/router.py

@@ -223,6 +223,8 @@ def bcast():
             except Exception: dead.append(q)
         for q in dead: sse_subscribers.remove(q)
 
+QUEUE_TIMEOUT = int(os.environ.get("QUEUE_TIMEOUT", "30"))  # max seconds to queue before 503
+
 @app.route("/v1/chat/completions", methods=["POST"])
 def chat():
     try:
@@ -230,11 +232,27 @@ def chat():
         ak = request.headers.get("Authorization","").replace("Bearer ","")
         ki = API_KEYS.get(ak, {"tier":"starter","agent":"unknown"})
         tier, agent = ki["tier"], ki["agent"]
+        
+        # Allow agent to override queue timeout via header
+        q_timeout = int(request.headers.get("X-Queue-Timeout", str(QUEUE_TIMEOUT)))
+        
         d = route(rd, tier)
-        if d.get("saturated"):
+        queue_start = time.time()
-            resp = jsonify({"error": "All GPUs saturated", "retry_after_s": 5})
+        
+        # Queue loop: wait for a GPU slot instead of immediate 503
+        while d.get("saturated"):
+            elapsed = time.time() - queue_start
+            if elapsed > q_timeout:
+                resp = jsonify({"error": "All GPUs saturated", "queued_s": round(elapsed,1), "retry_after_s": 5})
                 resp.headers["Retry-After"] = "5"
+                log.warning("QUEUE_TIMEOUT: %s waited %.1fs, all GPUs saturated", agent, elapsed)
                 return resp, 503
+            time.sleep(0.5)  # poll every 500ms
+            d = route(rd, tier)
+        
+        waited = time.time() - queue_start
+        if waited > 0.5:
+            log.info("QUEUED: %s waited %.1fs before slot opened", agent, waited)
         model, reason, url = d["model"], d["reason"], GPU_URLS[d["model"]]
         is_stream = rd.get("stream", False)