feat(S-102): Test-drive and implement --timeout flag, config layering, and default in

tools/ai-cli-dispatch/tests/cli.test.ts

@@ -39,6 +39,8 @@ describe("main", () => {
     stdout: "output",
     stderr: "",
     exitCode: 0,
+    client: "codex",
+    durationMs: 42,
   };
 
   it("returns 0 for --help and prints usage", async () => {
@@ -152,6 +154,8 @@ describe("main", () => {
             stdout: "hello-out",
             stderr: "hello-err",
             exitCode: 0,
+            client: "codex",
+            durationMs: 42,
           }),
           stdoutWrite: (chunk) => stdoutChunks.push(chunk),
           stderrWrite: (chunk) => stderrChunks.push(chunk),
@@ -259,7 +263,7 @@ describe("main", () => {
             return mockResult;
           },
           resolveClient: () => "claude",
-          resolveConfig: () => ({ paths: {} }),
+          resolveConfig: () => ({ paths: {}, timeout: 600_000 }),
         }
       );
       assert.strictEqual(code, 0);
@@ -286,7 +290,7 @@ describe("main", () => {
             return mockResult;
           },
           resolveClient: () => "codex",
-          resolveConfig: () => ({ paths: {} }),
+          resolveConfig: () => ({ paths: {}, timeout: 600_000 }),
         }
       );
       assert.strictEqual(code, 0);
@@ -310,7 +314,7 @@ describe("main", () => {
             return mockResult;
           },
           resolveClient: (_p, cfg) => cfg?.client ?? null,
-          resolveConfig: () => ({ paths: {}, defaultClient: "claude" }),
+          resolveConfig: () => ({ paths: {}, defaultClient: "claude", timeout: 600_000 }),
         }
       );
       assert.strictEqual(code, 0);
@@ -329,7 +333,7 @@ describe("main", () => {
           detectClients: () => mockClients,
           executePrompt: async () => mockResult,
           resolveClient: () => null,
-          resolveConfig: () => ({ paths: {} }),
+          resolveConfig: () => ({ paths: {}, timeout: 600_000 }),
         }
       );
       assert.strictEqual(code, 1);
@@ -351,7 +355,7 @@ describe("main", () => {
             throw new ClientNotFoundError("claude");
           },
           resolveClient: () => "claude",
-          resolveConfig: () => ({ paths: {} }),
+          resolveConfig: () => ({ paths: {}, timeout: 600_000 }),
         }
       );
       assert.strictEqual(code, 1);
@@ -388,9 +392,11 @@ describe("main", () => {
             stdout: "done",
             stderr: "",
             exitCode: 0,
+            client: "codex",
+            durationMs: 42,
           }),
           resolveClient: () => "codex",
-          resolveConfig: () => ({ paths: {} }),
+          resolveConfig: () => ({ paths: {}, timeout: 600_000 }),
           stdoutWrite: (chunk) => stdoutChunks.push(chunk),
         }
       );

tools/ai-cli-dispatch/tests/config.test.ts

@@ -135,4 +135,71 @@ describe("resolveConfig", () => {
     });
     assert.strictEqual(config.defaultClient, undefined);
   });
+
+  it("returns default timeout of 600000 when no sources are present", () => {
+    const config = resolveConfig({
+      existsSync: () => false,
+      whichSync: () => undefined,
+    });
+    assert.strictEqual(config.timeout, 600_000);
+  });
+
+  it("loads timeout from file config", () => {
+    const config = resolveConfig({
+      existsSync: () => true,
+      readFileSync: () => JSON.stringify({ timeout: 120_000 }),
+      whichSync: () => undefined,
+    });
+    assert.strictEqual(config.timeout, 120_000);
+  });
+
+  it("overrides file timeout with env var", () => {
+    const config = resolveConfig({
+      env: { AI_CLI_TIMEOUT: "240000" },
+      existsSync: () => true,
+      readFileSync: () => JSON.stringify({ timeout: 120_000 }),
+      whichSync: () => undefined,
+    });
+    assert.strictEqual(config.timeout, 240_000);
+  });
+
+  it("overrides env timeout with CLI flag", () => {
+    const config = resolveConfig({
+      flags: { timeout: "480000" },
+      env: { AI_CLI_TIMEOUT: "240000" },
+      existsSync: () => true,
+      readFileSync: () => JSON.stringify({ timeout: 120_000 }),
+      whichSync: () => undefined,
+    });
+    assert.strictEqual(config.timeout, 480_000);
+  });
+
+  it("respects full priority ordering for timeout: flag > env > file > default", () => {
+    const config = resolveConfig({
+      flags: { timeout: "480000" },
+      env: { AI_CLI_TIMEOUT: "240000" },
+      existsSync: () => true,
+      readFileSync: () => JSON.stringify({ timeout: 120_000 }),
+      whichSync: () => undefined,
+    });
+    assert.strictEqual(config.timeout, 480_000);
+  });
+
+  it("ignores invalid timeout from env var and falls back to default", () => {
+    const config = resolveConfig({
+      env: { AI_CLI_TIMEOUT: "not-a-number" },
+      existsSync: () => false,
+      whichSync: () => undefined,
+    });
+    assert.strictEqual(config.timeout, 600_000);
+  });
+
+  it("ignores invalid timeout from file and falls back to default", () => {
+    const config = resolveConfig({
+      existsSync: () => true,
+      readFileSync: () => JSON.stringify({ timeout: "not-a-number" }),
+      whichSync: () => undefined,
+    });
+    assert.strictEqual(config.timeout, 600_000);
+  });
 });

tools/ai-cli-dispatch/tests/execute.test.ts

@@ -203,4 +203,58 @@ describe("executePrompt", () => {
         err instanceof ExecError && err.message.includes("Unknown client")
     );
   });
+
+  it("includes client and durationMs in result", async () => {
+    const scenarios = new Map<string, MockScenario>([
+      ["codex exec --yolo hello", { stdout: "ok", exitCode: 0 }],
+    ]);
+    const result = await executePrompt("codex", "hello", {
+      spawn: mockSpawn(scenarios),
+      existsSync: () => true,
+    });
+    assert.strictEqual(result.client, "codex");
+    assert.strictEqual(typeof result.durationMs, "number");
+    assert.ok(result.durationMs >= 0);
+  });
+
+  it("rejects with ExecError containing custom timeout value", async () => {
+    const scenarios = new Map<string, MockScenario>([
+      ["codex exec --yolo slow", { hang: true }],
+    ]);
+    await assert.rejects(
+      executePrompt("codex", "slow", {
+        spawn: mockSpawn(scenarios),
+        existsSync: () => true,
+        timeoutMs: 50,
+      }),
+      (err: unknown) =>
+        err instanceof ExecError &&
+        err.message === "Execution timed out after 50ms" &&
+        err.result.exitCode === -1 &&
+        err.result.client === "codex" &&
+        typeof err.result.durationMs === "number"
+    );
+  });
+
+  it("uses default timeout of 600000 when timeoutMs is not provided", async () => {
+    const delays: number[] = [];
+    const origSetTimeout = global.setTimeout;
+    (global as any).setTimeout = function(callback: any, delay: number) {
+      delays.push(delay);
+      return origSetTimeout(callback, delay);
+    };
+
+    const scenarios = new Map<string, MockScenario>([
+      ["codex exec --yolo hello", { stdout: "ok", exitCode: 0 }],
+    ]);
+    try {
+      await executePrompt("codex", "hello", {
+        spawn: mockSpawn(scenarios),
+        existsSync: () => true,
+      });
+      assert.strictEqual(delays[0], 600_000);
+    } finally {
+      global.setTimeout = origSetTimeout;
+    }
+  });
 });