fix(providers): change cooldown tracking from provider to ModelKey

This enables proper key-switching when multiple API keys share the same
provider. Previously, when one key failed, all keys were blocked because
cooldown was tracked per-provider.

Now each (provider, model) combination has independent cooldown, allowing
fallback to alternate keys when one is rate limited.

Includes TestMultiKeyWithModelFallback and related failover tests.

pkg/providers/fallback.go

@@ -117,17 +117,19 @@ func (fc *FallbackChain) Execute(
 			return nil, context.Canceled
 		}
 
-		// Check cooldown.
+		// Check cooldown (per provider/model, not just provider).
-		if !fc.cooldown.IsAvailable(candidate.Provider) {
+		// This allows multi-key failover where different keys use different model names.
-			remaining := fc.cooldown.CooldownRemaining(candidate.Provider)
+		cooldownKey := ModelKey(candidate.Provider, candidate.Model)
+		if !fc.cooldown.IsAvailable(cooldownKey) {
+			remaining := fc.cooldown.CooldownRemaining(cooldownKey)
 			result.Attempts = append(result.Attempts, FallbackAttempt{
 				Provider: candidate.Provider,
 				Model:    candidate.Model,
 				Skipped:  true,
 				Reason:   FailoverRateLimit,
 				Error: fmt.Errorf(
-					"provider %s in cooldown (%s remaining)",
+					"%s in cooldown (%s remaining)",
-					candidate.Provider,
+					cooldownKey,
 					remaining.Round(time.Second),
 				),
 			})
@@ -141,7 +143,7 @@ func (fc *FallbackChain) Execute(
 
 		if err == nil {
 			// Success.
-			fc.cooldown.MarkSuccess(candidate.Provider)
+			fc.cooldown.MarkSuccess(cooldownKey)
 			result.Response = resp
 			result.Provider = candidate.Provider
 			result.Model = candidate.Model
@@ -187,7 +189,7 @@ func (fc *FallbackChain) Execute(
 		}
 
 		// Retriable error: mark failure and continue to next candidate.
-		fc.cooldown.MarkFailure(candidate.Provider, failErr.Reason)
+		fc.cooldown.MarkFailure(cooldownKey, failErr.Reason)
 		result.Attempts = append(result.Attempts, FallbackAttempt{
 			Provider: candidate.Provider,
 			Model:    candidate.Model,

pkg/providers/fallback_multikey_test.go

@@ -0,0 +1,384 @@
+package providers
+
+import (
+	"context"
+	"errors"
+	"testing"
+)
+
+// TestMultiKeyFailover tests the complete failover flow with multiple API keys.
+// This simulates the config expansion scenario where api_keys: ["key1", "key2", "key3"]
+// is expanded into primary + fallbacks.
+func TestMultiKeyFailover(t *testing.T) {
+	// Simulate expanded config: primary with 2 fallbacks
+	// This is what ExpandMultiKeyModels would produce for api_keys: ["key1", "key2", "key3"]
+	cfg := ModelConfig{
+		Primary:   "glm-4.7",
+		Fallbacks: []string{"glm-4.7__key_1", "glm-4.7__key_2"},
+	}
+
+	candidates := ResolveCandidates(cfg, "zhipu")
+
+	if len(candidates) != 3 {
+		t.Fatalf("expected 3 candidates, got %d: %v", len(candidates), candidates)
+	}
+
+	// Create fallback chain
+	cooldown := NewCooldownTracker()
+	chain := NewFallbackChain(cooldown)
+
+	// Mock run function: first call fails with 429, second succeeds
+	callCount := 0
+	mockRun := func(ctx context.Context, provider, model string) (*LLMResponse, error) {
+		callCount++
+		if callCount == 1 {
+			// First call: simulate rate limit
+			return nil, errors.New("http error: status 429 - rate limit exceeded")
+		}
+		// Second call: success
+		return &LLMResponse{
+			Content: "Hello from key2!",
+		}, nil
+	}
+
+	// Execute fallback chain
+	result, err := chain.Execute(context.Background(), candidates, mockRun)
+	if err != nil {
+		t.Fatalf("expected success after failover, got error: %v", err)
+	}
+
+	if result == nil {
+		t.Fatal("expected result, got nil")
+	}
+
+	if result.Response.Content != "Hello from key2!" {
+		t.Errorf("expected response from key2, got: %s", result.Response.Content)
+	}
+
+	if callCount != 2 {
+		t.Errorf("expected 2 calls (1 fail + 1 success), got %d", callCount)
+	}
+
+	// Verify first attempt was recorded
+	if len(result.Attempts) != 1 {
+		t.Errorf("expected 1 failed attempt recorded, got %d", len(result.Attempts))
+	}
+
+	if result.Attempts[0].Reason != FailoverRateLimit {
+		t.Errorf(
+			"expected first attempt reason to be rate_limit, got: %s",
+			result.Attempts[0].Reason,
+		)
+	}
+}
+
+// TestMultiKeyFailoverAllFail tests when all keys hit rate limit
+func TestMultiKeyFailoverAllFail(t *testing.T) {
+	cfg := ModelConfig{
+		Primary:   "glm-4.7",
+		Fallbacks: []string{"glm-4.7__key_1", "glm-4.7__key_2"},
+	}
+
+	candidates := ResolveCandidates(cfg, "zhipu")
+
+	cooldown := NewCooldownTracker()
+	chain := NewFallbackChain(cooldown)
+
+	// Mock run function: all calls fail with rate limit
+	callCount := 0
+	mockRun := func(ctx context.Context, provider, model string) (*LLMResponse, error) {
+		callCount++
+		return nil, errors.New("status: 429 - too many requests")
+	}
+
+	// Execute fallback chain
+	result, err := chain.Execute(context.Background(), candidates, mockRun)
+
+	if err == nil {
+		t.Fatal("expected error when all keys fail, got nil")
+	}
+
+	if result != nil {
+		t.Errorf("expected nil result on failure, got: %v", result)
+	}
+
+	if callCount != 3 {
+		t.Errorf("expected 3 calls (all fail), got %d", callCount)
+	}
+
+	// Verify error type
+	var exhausted *FallbackExhaustedError
+	if !errors.As(err, &exhausted) {
+		t.Errorf("expected FallbackExhaustedError, got: %T - %v", err, err)
+	}
+
+	if len(exhausted.Attempts) != 3 {
+		t.Errorf("expected 3 attempts in exhausted error, got %d", len(exhausted.Attempts))
+	}
+}
+
+// TestMultiKeyFailoverCooldown tests that a key in cooldown is skipped
+func TestMultiKeyFailoverCooldown(t *testing.T) {
+	cfg := ModelConfig{
+		Primary:   "glm-4.7",
+		Fallbacks: []string{"glm-4.7__key_1"},
+	}
+
+	candidates := ResolveCandidates(cfg, "zhipu")
+
+	cooldown := NewCooldownTracker()
+	chain := NewFallbackChain(cooldown)
+
+	// Put the first model in cooldown (using ModelKey now, not just provider)
+	cooldownKey := ModelKey(candidates[0].Provider, candidates[0].Model)
+	cooldown.MarkFailure(cooldownKey, FailoverRateLimit)
+
+	// Verify it's not available
+	if cooldown.IsAvailable(cooldownKey) {
+		t.Fatal("expected first model to be in cooldown")
+	}
+
+	// Mock run function: only second should be called
+	callCount := 0
+	calledProviders := []string{}
+	mockRun := func(ctx context.Context, provider, model string) (*LLMResponse, error) {
+		callCount++
+		calledProviders = append(calledProviders, provider+"/"+model)
+		return &LLMResponse{Content: "success"}, nil
+	}
+
+	result, err := chain.Execute(context.Background(), candidates, mockRun)
+	if err != nil {
+		t.Fatalf("expected success, got error: %v", err)
+	}
+
+	// First provider should have been skipped
+	if callCount != 1 {
+		t.Errorf("expected 1 call (first skipped due to cooldown), got %d", callCount)
+	}
+
+	// Should have called the second provider/model
+	if len(calledProviders) != 1 ||
+		calledProviders[0] != candidates[1].Provider+"/"+candidates[1].Model {
+		t.Errorf("expected second model to be called, got: %v", calledProviders)
+	}
+
+	// Verify first attempt was recorded as skipped
+	if len(result.Attempts) != 1 {
+		t.Fatalf("expected 1 attempt (skipped), got %d", len(result.Attempts))
+	}
+
+	if !result.Attempts[0].Skipped {
+		t.Error("expected first attempt to be marked as skipped")
+	}
+}
+
+// TestMultiKeyFailoverWithFormatError tests that format errors are non-retriable
+func TestMultiKeyFailoverWithFormatError(t *testing.T) {
+	cfg := ModelConfig{
+		Primary:   "glm-4.7",
+		Fallbacks: []string{"glm-4.7__key_1"},
+	}
+
+	candidates := ResolveCandidates(cfg, "zhipu")
+
+	cooldown := NewCooldownTracker()
+	chain := NewFallbackChain(cooldown)
+
+	// Mock run function: first call fails with format error (bad request)
+	callCount := 0
+	mockRun := func(ctx context.Context, provider, model string) (*LLMResponse, error) {
+		callCount++
+		return nil, errors.New("invalid request format: tool_use.id missing")
+	}
+
+	// Execute fallback chain
+	result, err := chain.Execute(context.Background(), candidates, mockRun)
+
+	if err == nil {
+		t.Fatal("expected error for format failure, got nil")
+	}
+
+	// Format errors should NOT trigger failover (non-retriable)
+	// So we should only have 1 call
+	if callCount != 1 {
+		t.Errorf("expected 1 call (format error is non-retriable), got %d", callCount)
+	}
+
+	// Verify the error is a FailoverError with format reason
+	var failoverErr *FailoverError
+	if !errors.As(err, &failoverErr) {
+		t.Errorf("expected FailoverError, got: %T - %v", err, err)
+	}
+
+	if failoverErr.Reason != FailoverFormat {
+		t.Errorf("expected FailoverFormat reason, got: %s", failoverErr.Reason)
+	}
+
+	_ = result // result should be nil
+}
+
+// TestMultiKeyWithModelFallback tests multi-key failover combined with model fallback.
+// This simulates the scenario: api_keys: ["k1", "k2"] + fallbacks: ["minimax"]
+// Expected failover order: glm-4.7 (k1) → glm-4.7__key_1 (k2) → minimax
+func TestMultiKeyWithModelFallback(t *testing.T) {
+	// Simulate expanded config from:
+	// { "model_name": "glm-4.7", "api_keys": ["k1", "k2"], "fallbacks": ["minimax"] }
+	// After ExpandMultiKeyModels, primaryEntry.Fallbacks = ["glm-4.7__key_1", "minimax"]
+	// Note: In production, "minimax" would be resolved via model lookup to "minimax/minimax"
+	// In this test, we use the full format to avoid needing a lookup function.
+	cfg := ModelConfig{
+		Primary:   "glm-4.7",
+		Fallbacks: []string{"glm-4.7__key_1", "minimax/minimax"},
+	}
+
+	candidates := ResolveCandidates(cfg, "zhipu")
+
+	// Should have 3 candidates: glm-4.7 (zhipu), glm-4.7__key_1 (zhipu), minimax (minimax)
+	if len(candidates) != 3 {
+		t.Fatalf("expected 3 candidates, got %d: %v", len(candidates), candidates)
+	}
+
+	// Verify candidate order
+	if candidates[0].Model != "glm-4.7" || candidates[0].Provider != "zhipu" {
+		t.Errorf(
+			"expected first candidate to be zhipu/glm-4.7, got: %s/%s",
+			candidates[0].Provider,
+			candidates[0].Model,
+		)
+	}
+	if candidates[1].Model != "glm-4.7__key_1" || candidates[1].Provider != "zhipu" {
+		t.Errorf(
+			"expected second candidate to be zhipu/glm-4.7__key_1, got: %s/%s",
+			candidates[1].Provider,
+			candidates[1].Model,
+		)
+	}
+	if candidates[2].Model != "minimax" || candidates[2].Provider != "minimax" {
+		t.Errorf(
+			"expected third candidate to be minimax/minimax, got: %s/%s",
+			candidates[2].Provider,
+			candidates[2].Model,
+		)
+	}
+
+	cooldown := NewCooldownTracker()
+	chain := NewFallbackChain(cooldown)
+
+	// Mock run function: first two fail, third succeeds (model fallback)
+	callCount := 0
+	calledModels := []string{}
+	mockRun := func(ctx context.Context, provider, model string) (*LLMResponse, error) {
+		callCount++
+		calledModels = append(calledModels, provider+"/"+model)
+
+		switch callCount {
+		case 1:
+			// k1: rate limit
+			return nil, errors.New("status: 429 - rate limit")
+		case 2:
+			// k2: also rate limit (all zhipu keys exhausted)
+			return nil, errors.New("status: 429 - rate limit")
+		case 3:
+			// minimax: success
+			return &LLMResponse{Content: "success from minimax"}, nil
+		default:
+			return nil, errors.New("unexpected call")
+		}
+	}
+
+	result, err := chain.Execute(context.Background(), candidates, mockRun)
+	if err != nil {
+		t.Fatalf("expected success after failover to model fallback, got error: %v", err)
+	}
+
+	if callCount != 3 {
+		t.Errorf("expected 3 calls (k1 fail + k2 fail + minimax success), got %d", callCount)
+	}
+
+	if result.Response.Content != "success from minimax" {
+		t.Errorf("expected response from minimax, got: %s", result.Response.Content)
+	}
+
+	// Verify call order
+	if len(calledModels) != 3 {
+		t.Fatalf("expected 3 called models, got %d", len(calledModels))
+	}
+	if calledModels[0] != "zhipu/glm-4.7" {
+		t.Errorf("expected first call to zhipu/glm-4.7, got: %s", calledModels[0])
+	}
+	if calledModels[1] != "zhipu/glm-4.7__key_1" {
+		t.Errorf("expected second call to zhipu/glm-4.7__key_1, got: %s", calledModels[1])
+	}
+	if calledModels[2] != "minimax/minimax" {
+		t.Errorf("expected third call to minimax/minimax, got: %s", calledModels[2])
+	}
+
+	// Verify 2 failed attempts recorded
+	if len(result.Attempts) != 2 {
+		t.Errorf("expected 2 failed attempts, got %d", len(result.Attempts))
+	}
+
+	// Both should be rate limit
+	for i, attempt := range result.Attempts {
+		if attempt.Reason != FailoverRateLimit {
+			t.Errorf("expected attempt %d to be rate_limit, got: %s", i, attempt.Reason)
+		}
+	}
+}
+
+// TestMultiKeyFailoverMixedErrors tests failover with different error types
+func TestMultiKeyFailoverMixedErrors(t *testing.T) {
+	cfg := ModelConfig{
+		Primary:   "glm-4.7",
+		Fallbacks: []string{"glm-4.7__key_1", "glm-4.7__key_2"},
+	}
+
+	candidates := ResolveCandidates(cfg, "zhipu")
+
+	cooldown := NewCooldownTracker()
+	chain := NewFallbackChain(cooldown)
+
+	// Mock run function: different errors for each key
+	callCount := 0
+	mockRun := func(ctx context.Context, provider, model string) (*LLMResponse, error) {
+		callCount++
+		switch callCount {
+		case 1:
+			// First: rate limit (retriable)
+			return nil, errors.New("status: 429 - rate limit")
+		case 2:
+			// Second: timeout (retriable)
+			return nil, errors.New("context deadline exceeded")
+		case 3:
+			// Third: success
+			return &LLMResponse{Content: "success from key3"}, nil
+		default:
+			return nil, errors.New("unexpected call")
+		}
+	}
+
+	result, err := chain.Execute(context.Background(), candidates, mockRun)
+	if err != nil {
+		t.Fatalf("expected success after 2 failovers, got error: %v", err)
+	}
+
+	if callCount != 3 {
+		t.Errorf("expected 3 calls, got %d", callCount)
+	}
+
+	// Verify both failed attempts were recorded
+	if len(result.Attempts) != 2 {
+		t.Errorf("expected 2 failed attempts, got %d", len(result.Attempts))
+	}
+
+	// First should be rate limit
+	if result.Attempts[0].Reason != FailoverRateLimit {
+		t.Errorf("expected first attempt to be rate_limit, got: %s", result.Attempts[0].Reason)
+	}
+
+	// Second should be timeout
+	if result.Attempts[1].Reason != FailoverTimeout {
+		t.Errorf("expected second attempt to be timeout, got: %s", result.Attempts[1].Reason)
+	}
+}

pkg/providers/fallback_test.go

@@ -157,8 +157,8 @@ func TestFallback_CooldownSkip(t *testing.T) {
 	ct, _ := newTestTracker(now)
 	fc := NewFallbackChain(ct)
 
-	// Put openai in cooldown
+	// Put openai/gpt-4 in cooldown (using ModelKey now)
-	ct.MarkFailure("openai", FailoverRateLimit)
+	ct.MarkFailure(ModelKey("openai", "gpt-4"), FailoverRateLimit)
 
 	candidates := []FallbackCandidate{
 		makeCandidate("openai", "gpt-4"),
@@ -195,9 +195,9 @@ func TestFallback_AllInCooldown(t *testing.T) {
 	ct := NewCooldownTracker()
 	fc := NewFallbackChain(ct)
 
-	// Put all providers in cooldown
+	// Put all models in cooldown (using ModelKey now)
-	ct.MarkFailure("openai", FailoverRateLimit)
+	ct.MarkFailure(ModelKey("openai", "gpt-4"), FailoverRateLimit)
-	ct.MarkFailure("anthropic", FailoverBilling)
+	ct.MarkFailure(ModelKey("anthropic", "claude"), FailoverBilling)
 
 	candidates := []FallbackCandidate{
 		makeCandidate("openai", "gpt-4"),
@@ -273,12 +273,13 @@ func TestFallback_SuccessResetsCooldown(t *testing.T) {
 	fc := NewFallbackChain(ct)
 
 	candidates := []FallbackCandidate{makeCandidate("openai", "gpt-4")}
+	modelKey := ModelKey("openai", "gpt-4")
 
 	attempt := 0
 	run := func(ctx context.Context, provider, model string) (*LLMResponse, error) {
 		attempt++
 		if attempt == 1 {
-			ct.MarkFailure("openai", FailoverRateLimit) // simulate failure tracked elsewhere
+			ct.MarkFailure(modelKey, FailoverRateLimit) // simulate failure tracked elsewhere
 		}
 		return &LLMResponse{Content: "ok", FinishReason: "stop"}, nil
 	}
@@ -287,7 +288,7 @@ func TestFallback_SuccessResetsCooldown(t *testing.T) {
 	if err != nil {
 		t.Fatalf("unexpected error: %v", err)
 	}
-	if !ct.IsAvailable("openai") {
+	if !ct.IsAvailable(modelKey) {
 		t.Error("success should reset cooldown")
 	}
 }