[model-gateway] use worker startup time out for worker registration (#13473)

sgl-router/bindings/python/sglang_router/router.py

@@ -74,7 +74,7 @@ class Router:
             - PolicyType.PowerOfTwo: Select best of two random workers based on load (PD mode only)
         host: Host address to bind the router server. Supports IPv4, IPv6 (e.g., ::, ::1), or 0.0.0.0 for all interfaces. Default: '0.0.0.0'
         port: Port number to bind the router server. Default: 3001
-        worker_startup_timeout_secs: Timeout in seconds for worker startup. Default: 300
+        worker_startup_timeout_secs: Timeout in seconds for worker startup and registration. Large models can take significant time to load into GPU memory. Default: 1800 (30 minutes)
         worker_startup_check_interval: Interval in seconds between checks for worker initialization. Default: 10
         cache_threshold: Cache threshold (0.0-1.0) for cache-aware routing. Routes to cached worker
             if the match rate exceeds threshold, otherwise routes to the worker with the smallest

sgl-router/bindings/python/sglang_router/router_args.py

@@ -26,7 +26,7 @@ class RouterArgs:
     policy: str = "cache_aware"
     prefill_policy: Optional[str] = None  # Specific policy for prefill nodes in PD mode
     decode_policy: Optional[str] = None  # Specific policy for decode nodes in PD mode
-    worker_startup_timeout_secs: int = 600
+    worker_startup_timeout_secs: int = 1800
     worker_startup_check_interval: int = 30
     cache_threshold: float = 0.3
     balance_abs_threshold: int = 64
@@ -209,7 +209,7 @@ class RouterArgs:
             f"--{prefix}worker-startup-timeout-secs",
             type=int,
             default=RouterArgs.worker_startup_timeout_secs,
-            help="Timeout in seconds for worker startup",
+            help="Timeout in seconds for worker startup and registration (default: 1800 / 30 minutes). Large models can take significant time to load into GPU memory.",
         )
         parser.add_argument(
             f"--{prefix}worker-startup-check-interval",

sgl-router/src/config/types.rs

@@ -467,9 +467,9 @@ impl Default for RouterConfig {
             policy: PolicyConfig::Random,
             host: "0.0.0.0".to_string(),
             port: 3001,
-            max_payload_size: 536_870_912, // 512MB
-            request_timeout_secs: 1800,    // 30 minutes
-            worker_startup_timeout_secs: 600,
+            max_payload_size: 536_870_912,     // 512MB
+            request_timeout_secs: 1800,        // 30 minutes
+            worker_startup_timeout_secs: 1800, // 30 minutes for large model loading
             worker_startup_check_interval_secs: 30,
             dp_aware: false,
             api_key: None,
@@ -580,7 +580,7 @@ mod tests {
         assert_eq!(config.port, 3001);
         assert_eq!(config.max_payload_size, 536_870_912);
         assert_eq!(config.request_timeout_secs, 1800);
-        assert_eq!(config.worker_startup_timeout_secs, 600);
+        assert_eq!(config.worker_startup_timeout_secs, 1800);
         assert_eq!(config.worker_startup_check_interval_secs, 30);
         assert!(config.discovery.is_none());
         assert!(config.metrics.is_none());

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

@@ -898,10 +898,11 @@ impl StepExecutor for ActivateWorkerStep {
 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);
+    // Use startup timeout from config for worker registration
+    // This is separate from health_check.timeout_secs which is for individual HTTP requests
+    let detect_timeout = Duration::from_secs(router_config.worker_startup_timeout_secs);
 
-    // Calculate max_attempts to match the detect_timeout
+    // Calculate max_attempts to match the startup_timeout
     // With Linear backoff (increment 1s, max 5s):
     // - Attempts 1-5: 0s, 1s, 2s, 3s, 4s = 10s total
     // - Attempts 6+: 5s each

sgl-router/src/main.rs

@@ -126,7 +126,7 @@ struct CliArgs {
     #[arg(long, value_parser = ["random", "round_robin", "cache_aware", "power_of_two"])]
     decode_policy: Option<String>,
 
-    #[arg(long, default_value_t = 600)]
+    #[arg(long, default_value_t = 1800)]
     worker_startup_timeout_secs: u64,
 
     #[arg(long, default_value_t = 30)]