hermes: fail over malformed tool calls

services/hermes/agent-deployment.yaml

@@ -25,7 +25,7 @@ spec:
         ai.bstein.dev/execution: Hermes Kanban with durable direct Codex and Claude Code CLI workers
         ai.bstein.dev/model-policy: Jetson-assisted AUTO routing, low through xhigh, cross-provider fallback
         ai.bstein.dev/placement: rpi5 preferred; Jetson deferred until state storage is available
-        ai.bstein.dev/config-rev: "20260812-codex-stream-terminal"
+        ai.bstein.dev/config-rev: "20260812-tool-call-failover"
         vault.hashicorp.com/agent-inject: "true"
         vault.hashicorp.com/role: hermes-agent
         vault.hashicorp.com/agent-inject-secret-anthropic-token: kv/data/atlas/hermes/agent-tokens

services/hermes/scripts/codex_broker.py

@@ -212,6 +212,28 @@ def _completed_response(lines: Iterable[str]) -> dict[str, Any]:
             terminal_response["output"] = [
                 output_items[index] for index in sorted(output_items)
             ]
+        # A Responses stream can be marked ``completed`` even when a function
+        # call was cut off at the provider's output boundary.  Passing that
+        # downstream as HTTP 200 makes Hermes retry the same broken turn until
+        # it emits the unhelpful "Response truncated" message.  Reject malformed
+        # terminal tool calls here so Switchyard can fail over to another
+        # eligible provider/model for this boundary.
+        for item in terminal_response.get("output") or []:
+            if not isinstance(item, dict) or item.get("type") != "function_call":
+                continue
+            if str(item.get("status") or "completed").lower() == "incomplete":
+                raise RuntimeError("Codex returned a retryable incomplete tool call")
+            arguments = item.get("arguments")
+            if not isinstance(arguments, str):
+                raise RuntimeError("Codex returned malformed function arguments")
+            try:
+                parsed_arguments = json.loads(arguments)
+            except (TypeError, ValueError, json.JSONDecodeError) as exc:
+                raise RuntimeError(
+                    "Codex returned retryable malformed function arguments"
+                ) from exc
+            if not isinstance(parsed_arguments, dict):
+                raise RuntimeError("Codex returned malformed function arguments")
         return terminal_response
     raise RuntimeError(upstream_error or "Codex stream ended without a terminal response")
 

services/hermes/switchyard-configmap.yaml

@@ -208,6 +208,10 @@ data:
     analysis, or bounded architecture; low only for simple conversation,
     formatting, lookup, or mechanical reversible work. Never choose below the
     floor and never exceed xhigh.
+    If tools are present or the boundary may emit a tool call, the floor is
+    medium even when the user's wording is short. Filesystem, shell,
+    repository, cluster, browser, and image-generation/edit operations are
+    tool work; never route those boundaries to Luna, Haiku, or local-low.
 
     2. Treat "think hard", "deeply", "carefully", and equivalent intent as a
     request to raise capability by at least one tier when the safety floor is
@@ -266,6 +270,10 @@ data:
     analysis, or bounded architecture; low only for simple conversation,
     formatting, lookup, or mechanical reversible work. Never choose below the
     floor and never exceed xhigh.
+    If tools are present or the boundary may emit a tool call, the floor is
+    medium even when the user's wording is short. Filesystem, shell,
+    repository, cluster, browser, and image-generation/edit operations are
+    tool work; never route those boundaries to Luna, Haiku, or local-low.
 
     2. Treat "think hard", "deeply", "carefully", and equivalent intent as a
     request to raise capability by at least one tier when the safety floor is
@@ -324,6 +332,10 @@ data:
     ordinary diagnosis, implementation, tool use, analysis, or bounded
     architecture; low only for simple notification summaries, lookup, or
     mechanical reversible work. Never choose below the floor or above xhigh.
+    If tools are present or the boundary may emit a tool call, the floor is
+    medium even when the user's wording is short. Filesystem, shell,
+    repository, cluster, browser, and image-generation/edit operations are
+    tool work; never route those boundaries to Luna or Haiku.
 
     2. Treat "think hard", "deeply", "carefully", and equivalent intent as a
     request to raise capability by at least one tier when the safety floor is
@@ -383,6 +395,10 @@ data:
     implementation, tests, tool use, analysis, or bounded architecture; low
     only for lookup or truly mechanical reversible work. Never choose below the
     floor or above xhigh.
+    If tools are present or the boundary may emit a tool call, the floor is
+    medium even when the user's wording is short. Filesystem, shell,
+    repository, cluster, browser, and image-generation/edit operations are
+    tool work; never route those boundaries to Luna or Haiku.
 
     2. Treat "think hard", "deeply", "carefully", and equivalent intent as a
     request to raise capability by at least one tier when the safety floor is

services/hermes/switchyard-deployment.yaml

@@ -22,7 +22,7 @@ spec:
       labels:
         app: hermes-switchyard
       annotations:
-        ai.bstein.dev/config-rev: "20260812-quality-route-local-exclusion"
+        ai.bstein.dev/config-rev: "20260812-tool-call-effort-floor"
         prometheus.io/scrape: "true"
         prometheus.io/port: "9005"
         prometheus.io/path: /metrics

testing/tests/test_hermes_chat_quality.py

@@ -700,6 +700,49 @@ def test_codex_broker_auth_and_request_contract(tmp_path: Path, monkeypatch):
                 'data: {"type":"error","error":{"message":"provider unavailable"}}',
             ]
         )
+    malformed_tool_item = {
+        "type": "function_call",
+        "name": "search_files",
+        "status": "completed",
+        "arguments": '{"path":"","offset":',
+    }
+    with pytest.raises(RuntimeError, match="malformed function arguments"):
+        module._completed_response(
+            [
+                "event: response.output_item.done",
+                "data: "
+                + json.dumps(
+                    {
+                        "type": "response.output_item.done",
+                        "output_index": 0,
+                        "item": malformed_tool_item,
+                    }
+                ),
+                "event: response.completed",
+                "data: "
+                + json.dumps({"type": "response.completed", "response": completed}),
+            ]
+        )
+    valid_tool_item = {
+        **malformed_tool_item,
+        "arguments": '{"path":"","offset":0}',
+    }
+    assert module._completed_response(
+        [
+            "event: response.output_item.done",
+            "data: "
+            + json.dumps(
+                {
+                    "type": "response.output_item.done",
+                    "output_index": 0,
+                    "item": valid_tool_item,
+                }
+            ),
+            "event: response.completed",
+            "data: "
+            + json.dumps({"type": "response.completed", "response": completed}),
+        ]
+    )["output"] == [valid_tool_item]
 
     auth_dir = tmp_path / ".codex"
     auth_dir.mkdir()