fix(tools): validate handler return types at dispatch boundary

Fixes #297

Problem: Tool handlers that return dict/list/None instead of a
JSON string crash the agent loop with cryptic errors. No error
proofing at the boundary.
Fix: In handle_function_call(), after dispatch returns:
1. If result is not str → wrap in JSON with _type_warning
2. If result is str but not valid JSON → wrap in {"output": ...}
3. Log type violations for analysis
4. Valid JSON strings pass through unchanged

Tests: 4 new tests (dict, None, non-JSON string, valid JSON).
All 16 tests in test_model_tools.py pass.

model_tools.py

@@ -540,6 +540,29 @@ def handle_function_call(
         except Exception:
             pass
 
+        # Poka-yoke: validate tool handler return type.
+        # Handlers MUST return a JSON string. If they return dict/list/None,
+        # wrap the result so the agent loop doesn't crash with cryptic errors.
+        if not isinstance(result, str):
+            logger.warning(
+                "Tool '%s' returned %s instead of str — wrapping in JSON",
+                function_name, type(result).__name__,
+            )
+            result = json.dumps(
+                {"output": str(result), "_type_warning": f"Tool returned {type(result).__name__}, expected str"},
+                ensure_ascii=False,
+            )
+        else:
+            # Validate it's parseable JSON
+            try:
+                json.loads(result)
+            except (json.JSONDecodeError, TypeError):
+                logger.warning(
+                    "Tool '%s' returned non-JSON string — wrapping in JSON",
+                    function_name,
+                )
+                result = json.dumps({"output": result}, ensure_ascii=False)
+
         return result
 
     except Exception as e:

tests/test_model_tools.py

@@ -137,3 +137,78 @@ class TestBackwardCompat:
     def test_tool_to_toolset_map(self):
         assert isinstance(TOOL_TO_TOOLSET_MAP, dict)
         assert len(TOOL_TO_TOOLSET_MAP) > 0
+
+
+class TestToolReturnTypeValidation:
+    """Poka-yoke: tool handlers must return JSON strings."""
+
+    def test_handler_returning_dict_is_wrapped(self, monkeypatch):
+        """A handler that returns a dict should be auto-wrapped to JSON string."""
+        from tools.registry import registry
+        from model_tools import handle_function_call
+        import json
+
+        # Register a bad handler that returns dict instead of str
+        registry.register(
+            name="__test_bad_dict",
+            toolset="test",
+            schema={"name": "__test_bad_dict", "description": "test", "parameters": {"type": "object", "properties": {}}},
+            handler=lambda args, **kw: {"this is": "a dict not a string"},
+        )
+        result = handle_function_call("__test_bad_dict", {})
+        parsed = json.loads(result)
+        assert "output" in parsed
+        assert "_type_warning" in parsed
+        # Cleanup
+        registry._tools.pop("__test_bad_dict", None)
+
+    def test_handler_returning_none_is_wrapped(self, monkeypatch):
+        """A handler that returns None should be auto-wrapped."""
+        from tools.registry import registry
+        from model_tools import handle_function_call
+        import json
+
+        registry.register(
+            name="__test_bad_none",
+            toolset="test",
+            schema={"name": "__test_bad_none", "description": "test", "parameters": {"type": "object", "properties": {}}},
+            handler=lambda args, **kw: None,
+        )
+        result = handle_function_call("__test_bad_none", {})
+        parsed = json.loads(result)
+        assert "_type_warning" in parsed
+        registry._tools.pop("__test_bad_none", None)
+
+    def test_handler_returning_non_json_string_is_wrapped(self):
+        """A handler returning a plain string (not JSON) should be wrapped."""
+        from tools.registry import registry
+        from model_tools import handle_function_call
+        import json
+
+        registry.register(
+            name="__test_bad_plain",
+            toolset="test",
+            schema={"name": "__test_bad_plain", "description": "test", "parameters": {"type": "object", "properties": {}}},
+            handler=lambda args, **kw: "just a plain string, not json",
+        )
+        result = handle_function_call("__test_bad_plain", {})
+        parsed = json.loads(result)
+        assert "output" in parsed
+        registry._tools.pop("__test_bad_plain", None)
+
+    def test_handler_returning_valid_json_passes_through(self):
+        """A handler returning valid JSON string passes through unchanged."""
+        from tools.registry import registry
+        from model_tools import handle_function_call
+        import json
+
+        registry.register(
+            name="__test_good",
+            toolset="test",
+            schema={"name": "__test_good", "description": "test", "parameters": {"type": "object", "properties": {}}},
+            handler=lambda args, **kw: json.dumps({"status": "ok", "data": [1, 2, 3]}),
+        )
+        result = handle_function_call("__test_good", {})
+        parsed = json.loads(result)
+        assert parsed == {"status": "ok", "data": [1, 2, 3]}
+        registry._tools.pop("__test_good", None)