front: route to a pinned/owning engine that's busy, not a duplicate elsewhere

An engine mid-generation is GIL-blocked and fails the health poll, so it
reads as unhealthy. pick_engine required e.healthy at every step, so a
second request for a model pinned to that engine fell through to the
least-loaded engine — which loaded a DUPLICATE copy (and ignored the
model's configured n_ctx, e.g. 2048 vs 32000 → "exceeds context window").

Honour the pin (and the assigned owner) when the engine is alive but
transiently busy: route there so the request queues on its gen-lock and
the owner handles serialization/eviction. Only fall back to another engine
when the owner's process is actually dead. Adds Engine.is_alive() (process
liveness) and registry.engine_owning() (health-agnostic owner lookup).
Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

codai/frontproxy/registry.py

@@ -83,6 +83,19 @@ class Engine:
     def can_serve(self, required_cap: Optional[str]) -> bool:
         return (not required_cap) or (required_cap in self.capabilities)
 
+    def is_alive(self) -> bool:
+        """Process is up (so 'unhealthy' means busy/GIL-blocked, not dead).
+
+        An engine mid-generation can't answer the health poll and reads as
+        unhealthy, but it's the right place to send a request pinned/assigned to
+        it — the request queues on its gen-lock instead of duplicating the model
+        elsewhere. A None proc means externally managed; assume alive."""
+        p = self.proc
+        try:
+            return p is None or p.poll() is None
+        except Exception:
+            return True
+
 
 class EngineRegistry:
     def __init__(self):
@@ -192,6 +205,24 @@ class EngineRegistry:
                         return e
         return None
 
+    def engine_owning(self, model_key: str) -> Optional[Engine]:
+        """The engine ASSIGNED this model, regardless of current health.
+
+        Like engine_for_assigned but without the healthy filter — so a request can
+        be routed to its owner while the owner is transiently busy (mid-generation,
+        failing health polls) and queue there, rather than spawning a duplicate on
+        another engine. Callers should gate on ``is_alive()``."""
+        if not model_key:
+            return None
+        short = _short_stem(model_key)
+        with self._lock:
+            for e in self._engines.values():
+                for k in e.assigned_models:
+                    if (k == model_key or _short_stem(k) == short
+                            or k.endswith(model_key) or model_key.endswith(k.split("/")[-1])):
+                        return e
+        return None
+
     def least_loaded(self, required_cap: Optional[str] = None) -> Optional[Engine]:
         """Pick a healthy, capability-compatible engine to load a new model on:
         fewest resident models, then most free VRAM."""

codai/frontproxy/router.py

@@ -123,10 +123,17 @@ def pick_engine(registry: EngineRegistry, path: str, method: str,
         # 1. Per-model pin (models.json "engine") — only honoured if compatible.
         if pinned:
             e = registry.by_name(pinned)
-            if e and e.healthy and e.can_serve(cap):
+            if e and e.can_serve(cap):
+                if e.healthy:
+                    return e
+                # Pinned engine is busy (mid-generation → failing health polls) but
+                # its process is alive: route here anyway so the request queues on
+                # its gen-lock, instead of duplicating a pinned model on another
+                # engine (which also ignores its configured n_ctx etc.).
+                if e.is_alive():
                     return e
-            # Pin can't be honoured — say why (once per model+engine) instead of
-            # silently falling back, so a misconfiguration is visible in the logs.
+            # Pin can't be honoured (engine down or incompatible) — say why (once
+            # per model+engine) instead of silently falling back.
             _warn_bad_pin(model, pinned, cap, e)
 
         # 2. Engine that already has the model resident.
@@ -135,13 +142,20 @@ def pick_engine(registry: EngineRegistry, path: str, method: str,
             if e:
                 return e
 
-        # 3. Configured default engine, when it can serve this request.
+        # 3. The assigned owner, busy-but-alive: prefer queueing on the engine that
+        # owns this model over loading a second copy on a different one.
+        if model:
+            owner = registry.engine_owning(model)
+            if owner is not None and owner.can_serve(cap) and owner.is_alive():
+                return owner
+
+        # 4. Configured default engine, when it can serve this request.
         if default_engine:
             e = registry.by_name(default_engine)
             if e and e.healthy and e.can_serve(cap):
                 return e
 
-        # 4. Least-loaded compatible engine; then any engine rather than 503.
+        # 5. Least-loaded compatible engine; then any engine rather than 503.
         return (registry.least_loaded(cap)
                 or registry.least_loaded(None)
                 or registry.primary())