[router] configure workflow retries and timeout based on routerConfig (#12252)

.github/workflows/pr-test-rust.yml

@@ -154,7 +154,7 @@ jobs:
   pytest-rust-2:
     if: github.event_name != 'pull_request' || contains(github.event.pull_request.labels.*.name, 'run-ci')
     runs-on: 4-gpu-a10
-    timeout-minutes: 16
+    timeout-minutes: 32
     steps:
       - name: Checkout code
         uses: actions/checkout@v4

sgl-router/src/core/workflow/steps/worker_registration.rs

@@ -820,7 +820,29 @@ impl StepExecutor for ActivateWorkerStep {
 /// Note: Actual health check timeouts and retry attempts are configured per-worker
 /// via WorkerConfigRequest (populated from router config). The timeouts and retry
 /// policies here serve as workflow-level bounds to prevent infinite waiting.
-pub fn create_worker_registration_workflow() -> WorkflowDefinition {
+///
+/// # Arguments
+/// * `router_config` - Router configuration containing health check settings
+pub fn create_worker_registration_workflow(
+    router_config: &crate::config::RouterConfig,
+) -> WorkflowDefinition {
+    // Use health check timeout from config with 30 second buffer as workflow-level upper bound
+    let detect_timeout = Duration::from_secs(router_config.health_check.timeout_secs + 30);
+
+    // Calculate max_attempts to match the detect_timeout
+    // With Linear backoff (increment 1s, max 5s):
+    // - Attempts 1-5: 0s, 1s, 2s, 3s, 4s = 10s total
+    // - Attempts 6+: 5s each
+    // max_attempts = 5 + (timeout_seconds - 10) / 5
+    // Use 90% of timeout to leave buffer for actual connection attempts
+    let timeout_secs = detect_timeout.as_secs() as f64;
+    let effective_timeout = timeout_secs * 0.9;
+    let max_attempts = if effective_timeout > 10.0 {
+        (5 + ((effective_timeout - 10.0) / 5.0).ceil() as u32).max(3)
+    } else {
+        3
+    };
+
     WorkflowDefinition::new("worker_registration", "Worker Registration")
         .add_step(
             StepDefinition::new(
@@ -829,14 +851,14 @@ pub fn create_worker_registration_workflow() -> WorkflowDefinition {
                 Arc::new(DetectConnectionModeStep),
             )
             .with_retry(RetryPolicy {
-                max_attempts: 100,
+                max_attempts,
                 backoff: BackoffStrategy::Linear {
                     increment: Duration::from_secs(1),
                     max: Duration::from_secs(5),
                 },
             })
-            // Workflow-level timeout (upper bound); step uses config.health_check_timeout_secs
+            // Workflow-level timeout uses configured health check timeout + buffer
-            .with_timeout(Duration::from_secs(7200)) // 2 hours max
+            .with_timeout(detect_timeout)
             .with_failure_action(FailureAction::FailWorkflow),
         )
         .add_step(

sgl-router/src/server.rs

@@ -737,14 +737,17 @@ pub async fn startup(config: ServerConfig) -> Result<(), Box<dyn std::error::Err
         .subscribe(Arc::new(LoggingSubscriber))
         .await;
 
-    engine.register_workflow(create_worker_registration_workflow());
+    engine.register_workflow(create_worker_registration_workflow(&config.router_config));
     engine.register_workflow(create_worker_removal_workflow());
     engine.register_workflow(create_mcp_registration_workflow());
     app_context
         .workflow_engine
         .set(engine)
         .expect("WorkflowEngine should only be initialized once");
-    info!("Workflow engine initialized with worker and MCP registration workflows");
+    info!(
+        "Workflow engine initialized with worker and MCP registration workflows (health check timeout: {}s)",
+        config.router_config.health_check.timeout_secs
+    );
 
     info!(
         "Initializing workers for routing mode: {:?}",
@@ -764,6 +767,8 @@ pub async fn startup(config: ServerConfig) -> Result<(), Box<dyn std::error::Err
         .await
         .map_err(|e| format!("Failed to submit worker initialization job: {}", e))?;
 
+    info!("Worker initialization job submitted (will complete in background)");
+
     if let Some(mcp_config) = &config.router_config.mcp_config {
         info!("Found {} MCP server(s) in config", mcp_config.servers.len());
         let mcp_job = Job::InitializeMcpServers {

sgl-router/tests/common/mod.rs

@@ -69,7 +69,7 @@ pub async fn create_test_context(config: RouterConfig) -> Arc<AppContext> {
 
     let app_context = Arc::new(
         AppContext::builder()
-            .router_config(config)
+            .router_config(config.clone())
             .client(client)
             .rate_limiter(rate_limiter)
             .tokenizer(None) // tokenizer
@@ -104,7 +104,7 @@ pub async fn create_test_context(config: RouterConfig) -> Arc<AppContext> {
         create_worker_registration_workflow, create_worker_removal_workflow, WorkflowEngine,
     };
     let engine = Arc::new(WorkflowEngine::new());
-    engine.register_workflow(create_worker_registration_workflow());
+    engine.register_workflow(create_worker_registration_workflow(&config));
     engine.register_workflow(create_worker_removal_workflow());
     app_context
         .workflow_engine
@@ -180,7 +180,7 @@ pub async fn create_test_context_with_mcp_config(
 
     let app_context = Arc::new(
         AppContext::builder()
-            .router_config(config)
+            .router_config(config.clone())
             .client(client)
             .rate_limiter(rate_limiter)
             .tokenizer(None) // tokenizer
@@ -215,7 +215,7 @@ pub async fn create_test_context_with_mcp_config(
         create_worker_registration_workflow, create_worker_removal_workflow, WorkflowEngine,
     };
     let engine = Arc::new(WorkflowEngine::new());
-    engine.register_workflow(create_worker_registration_workflow());
+    engine.register_workflow(create_worker_registration_workflow(&config));
     engine.register_workflow(create_worker_removal_workflow());
     app_context
         .workflow_engine