Fix CF-271: Add fallback text search to archive_search

When LiteLLM embedding service is unavailable, archive_search now gracefully falls back to PostgreSQL text search (ILIKE) instead of returning an error. Also adds dotenv support for proper credential loading.

Co-Authored-By: Claude Sonnet 4.5 <noreply@anthropic.com>

.gitignore

@@ -1,3 +1,4 @@
 node_modules/
 dist/
 *.log
+.env

package-lock.json

@@ -9,6 +9,7 @@
       "version": "1.0.0",
       "dependencies": {
         "@modelcontextprotocol/sdk": "^1.0.4",
+        "dotenv": "^17.2.3",
         "pg": "^8.11.3"
       },
       "devDependencies": {
@@ -734,6 +735,18 @@
         "node": ">= 0.8"
       }
     },
+    "node_modules/dotenv": {
+      "version": "17.2.3",
+      "resolved": "https://registry.npmjs.org/dotenv/-/dotenv-17.2.3.tgz",
+      "integrity": "sha512-JVUnt+DUIzu87TABbhPmNfVdBDt18BLOWjMUFJMSi/Qqg7NTYtabbvSNJGOJ7afbRuv9D/lngizHtP7QyLQ+9w==",
+      "license": "BSD-2-Clause",
+      "engines": {
+        "node": ">=12"
+      },
+      "funding": {
+        "url": "https://dotenvx.com"
+      }
+    },
     "node_modules/dunder-proto": {
       "version": "1.0.1",
       "resolved": "https://registry.npmjs.org/dunder-proto/-/dunder-proto-1.0.1.tgz",

package.json

@@ -12,12 +12,13 @@
   },
   "dependencies": {
     "@modelcontextprotocol/sdk": "^1.0.4",
+    "dotenv": "^17.2.3",
     "pg": "^8.11.3"
   },
   "devDependencies": {
     "@types/node": "^20.11.0",
     "@types/pg": "^8.10.9",
-    "typescript": "^5.3.3",
-    "tsx": "^4.7.0"
+    "tsx": "^4.7.0",
+    "typescript": "^5.3.3"
   }
 }

src/embeddings.ts

@@ -1,8 +1,5 @@
 // Embeddings via LiteLLM API
 
-const LLM_API_URL = process.env.LLM_API_URL || 'https://api.agiliton.cloud/llm';
-const LLM_API_KEY = process.env.LLM_API_KEY || '';
-
 interface EmbeddingResponse {
   data: Array<{
     embedding: number[];
@@ -19,8 +16,13 @@ interface EmbeddingResponse {
  * Generate embedding for text using LiteLLM API
  */
 export async function getEmbedding(text: string): Promise<number[] | null> {
+  // Read env vars at runtime (after dotenv.config() in index.ts)
+  const LLM_API_URL = process.env.LLM_API_URL || 'https://api.agiliton.cloud/llm';
+  const LLM_API_KEY = process.env.LLM_API_KEY || '';
+
   if (!LLM_API_KEY) {
-    console.error('LLM_API_KEY not set, skipping embedding');
+    console.error('LLM_API_KEY not set, skipping embedding (check .env file)');
+    console.error('LLM_API_URL:', LLM_API_URL);
     return null;
   }
 

src/index.ts

@@ -9,6 +9,25 @@
  *   ssh -L 5433:localhost:5432 -i ~/.ssh/hetzner_mash_deploy root@46.224.188.157 -N &
  */
 
+// Load environment variables from .env file
+import dotenv from 'dotenv';
+import { fileURLToPath } from 'url';
+import { dirname, join } from 'path';
+
+const __filename = fileURLToPath(import.meta.url);
+const __dirname = dirname(__filename);
+const envPath = join(__dirname, '..', '.env');
+const result = dotenv.config({ path: envPath, override: true });
+
+// Log environment loading status (goes to MCP server logs)
+if (result.error) {
+  console.error('Failed to load .env from:', envPath, result.error);
+} else {
+  console.error('Loaded .env from:', envPath);
+  console.error('LLM_API_KEY present:', !!process.env.LLM_API_KEY);
+  console.error('LLM_API_URL:', process.env.LLM_API_URL);
+}
+
 import { Server } from '@modelcontextprotocol/sdk/server/index.js';
 import { StdioServerTransport } from '@modelcontextprotocol/sdk/server/stdio.js';
 import {

src/tools/archives.ts

@@ -125,10 +125,54 @@ export async function archiveSearch(args: ArchiveSearchArgs): Promise<string> {
   // Generate embedding for search
   const embedding = await getEmbedding(searchQuery);
 
+  // Fallback to text search if embeddings unavailable
   if (!embedding) {
-    return 'Error: Could not generate embedding for search';
+    console.warn('Embeddings unavailable, falling back to text search');
+
+    let whereClause = '(title ILIKE $1 OR content ILIKE $1)';
+    const params: unknown[] = [`%${searchQuery}%`];
+    let paramIndex = 2;
+
+    if (project) {
+      whereClause += ` AND project_key = $${paramIndex++}`;
+      params.push(project);
+    }
+    if (archive_type) {
+      whereClause += ` AND archive_type = $${paramIndex++}`;
+      params.push(archive_type);
+    }
+
+    params.push(limit);
+
+    const archives = await query<Archive>(
+      `SELECT id, archive_type, title, original_path, file_size,
+              to_char(archived_at, 'YYYY-MM-DD') as archived_at
+       FROM project_archives
+       WHERE ${whereClause}
+       ORDER BY archived_at DESC
+       LIMIT $${paramIndex}`,
+      params
+    );
+
+    if (archives.length === 0) {
+      return 'No relevant archives found';
+    }
+
+    const lines = ['Relevant archives (text search - embeddings unavailable):\n'];
+    for (const a of archives) {
+      const sizeStr = a.file_size ? ` (${Math.round(a.file_size / 1024)}KB)` : '';
+      lines.push(`**[${a.archive_type}]** ${a.title}`);
+      lines.push(`  Archived: ${a.archived_at}${sizeStr}`);
+      if (a.original_path) {
+        lines.push(`  Path: ${a.original_path}`);
+      }
+      lines.push('');
+    }
+
+    return lines.join('\n');
   }
 
+  // Semantic search with embeddings
   const embeddingStr = formatEmbedding(embedding);
 
   let whereClause = 'WHERE embedding IS NOT NULL';