fix(openrouter): ignored when tools are configured but unused

[icecrasher321]

Summary

Should not ignore when tools are unused but active.

Type of Change

• Bug fix

Testing

Tested manually.

Checklist

• Code follows project style guidelines
• Self-reviewed my changes
• Tests added/updated and passing
• No new warnings introduced
• I confirm that I have read and agree to the terms outlined in the Contributor License Agreement (CLA)

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1 Skipped Deployment

Project	Deployment	Review	Updated (UTC)
docs	Skipped		Jan 28, 2026 3:40am

[greptile-apps]

Greptile Overview

Greptile Summary

Fixed a logic bug in the OpenRouter provider where structured output formatting (responseFormat) was incorrectly skipped when tools were configured but not invoked by the model.

Key Changes:

• Removed the toolCalls.length > 0 condition from line 519, changing the logic to apply responseFormat whenever tools are active, regardless of whether they were actually called

Impact:

• Previously, if tools were configured (hasActiveTools = true) but the model chose not to use them (toolCalls.length = 0), the final structured output request would be skipped
• This fix ensures responseFormat is properly applied in the final response when tools are available but unused

Confidence Score: 5/5

• This PR is safe to merge with no risk
• The change is a simple, correct bug fix that removes an overly restrictive condition. The logic is sound: responseFormat should be applied when tools are configured (hasActiveTools), regardless of whether the model actually invoked them. The fix aligns with the intended behavior and has been manually tested.
• No files require special attention

Important Files Changed

Filename	Overview
apps/sim/providers/openrouter/index.ts	Fixed logic bug where responseFormat was skipped when tools were configured but unused

Sequence Diagram

sequenceDiagram
    participant Client
    participant OpenRouterProvider
    participant OpenAI_API as OpenRouter API
    participant Tools

    Client->>OpenRouterProvider: executeRequest(request with tools & responseFormat)
    OpenRouterProvider->>OpenRouterProvider: prepareToolsWithUsageControl()
    OpenRouterProvider->>OpenRouterProvider: hasActiveTools = true
    
    OpenRouterProvider->>OpenAI_API: Initial API call with tools
    OpenAI_API-->>OpenRouterProvider: Response (no tool calls)
    
    Note over OpenRouterProvider: toolCalls.length = 0<br/>(model didn't use tools)
    
    alt OLD BEHAVIOR (Bug)
        OpenRouterProvider->>OpenRouterProvider: Check: hasActiveTools && toolCalls.length > 0
        Note over OpenRouterProvider: Condition FALSE<br/>Skip responseFormat
        OpenRouterProvider-->>Client: Return without structured output
    end
    
    alt NEW BEHAVIOR (Fixed)
        OpenRouterProvider->>OpenRouterProvider: Check: hasActiveTools
        Note over OpenRouterProvider: Condition TRUE<br/>Apply responseFormat
        OpenRouterProvider->>OpenAI_API: Final call with responseFormat
        OpenAI_API-->>OpenRouterProvider: Structured JSON response
        OpenRouterProvider-->>Client: Return with structured output
    end

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[greptile-apps]

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