Enhance bulk booking handling and wagon capacity calculations across services

apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.ts

@@ -1,6 +1,8 @@
 import {
   BadRequestException,
   ConflictException,
+  forwardRef,
+  Inject,
   Injectable,
   Logger,
   NotFoundException,
@@ -13,6 +15,7 @@ import { DataSource, In } from 'typeorm';
 
 import { Booking } from '../bookings/entities/booking.entity';
 import { BookingsRepository } from '../bookings/bookings.repository';
+import { BookingPricingService } from '../bookings/booking-pricing.service';
 import { Locomotive } from '../locomotives/entities/locomotive.entity';
 import { formatRouteLabel } from '../routes/entities/route.entity';
 import { RouteMilestone } from '../routes/entities/route-milestone.entity';
@@ -42,6 +45,7 @@ import {
   bookingGrossWeightTons,
   bookingTrainLengthMeters,
   deriveTrainCapacityFromLocomotive,
+  sizePartialOfferWagons,
   trainHardCaps,
   wagonTypeDimensionsFromEntity,
 } from './train-capacity.util';
@@ -239,6 +243,8 @@ export class BookingBatchService implements OnModuleInit {
     private readonly trainSchedulingService: TrainSchedulingService,
     private readonly billing: BillingService,
     private readonly bookingWindowGateway: BookingWindowGateway,
+    @Inject(forwardRef(() => BookingPricingService))
+    private readonly pricingService: BookingPricingService,
 
     @Optional() private readonly milestoneService?: ClearanceMilestoneService,
     @Optional() private readonly splitService?: BookingSplitService,
@@ -1097,6 +1103,10 @@ export class BookingBatchService implements OnModuleInit {
     }
 
     const pool = await this.bookingsRepository.findBatchPool(scheduleId);
+    // Same bulk re-score as fillRouteDayInternal — the legacy per-schedule fill
+    // must rank bulk bookings by their wagon-derived priority too.
+    await this.recomputeBulkPriorities(pool, wagonDims);
+    this.resortPoolByPriority(pool);
     const units = this.groupConsolidatedPool(pool);
     let armed = false;
     let reservedThisPass = 0;
@@ -1314,6 +1324,10 @@ export class BookingBatchService implements OnModuleInit {
       corridorYards,
       day,
     );
+    // BULK bookings only get their real (wagon-derived) priority score now, at
+    // batch time — stamp it and re-rank before the fill consumes the pool.
+    await this.recomputeBulkPriorities(pool, wagonDims);
+    this.resortPoolByPriority(pool);
     // Consolidated partners collapse into one atomic unit (both-or-neither); a
     // consolidated booking whose partner isn't ready this cycle is skipped.
     const units = this.groupConsolidatedPool(pool);
@@ -1505,11 +1519,24 @@ export class BookingBatchService implements OnModuleInit {
 
     const wagonDims = await this.loadWagonDims();
     const bulkCapacityTons = await this.loadBulkWagonCapacityTons();
+
+    // The wagon-slot axis alone under-constrains the offer. On a weight- or
+    // length-limited train (slots to spare, but e.g. only 798T of pull weight
+    // left) sizing by slots either produced an offer the fits() check below
+    // rejected, or — when the free slots exceeded the booking's own wagon
+    // count — sizeOffer refused outright, so a bulk booking on a weight-bound
+    // train was never offered a split at all. Size across all three axes.
+    const perWagon =
+      booking.freightType === "BULK" ? wagonDims.bulk : wagonDims.container;
+    const partial = sizePartialOfferWagons(budget, need.wagons, perWagon);
+    if (!partial) return null;
+
     const sized = await this.splitService.sizeOffer(
       booking,
-      budget.wagons,
+      partial.wagons,
       need.wagons,
       bulkCapacityTons,
+      partial.maxCargoTons,
     );
     if (!sized) return null;
 
@@ -2284,6 +2311,56 @@ export class BookingBatchService implements OnModuleInit {
     };
   }
 
+  /**
+   * Stamp real priority scores on the pool's BULK bookings before the batch
+   * ranks it. Submit-time scoring runs with totalWagons = 0 for bulk (a bulk
+   * booking has no container lines to carry a wagon count), so every
+   * wagon-range priority config missed and bulk import bookings entered the
+   * batch at score 0 — they were never prioritized. Their wagon footprint is
+   * derivable from tonnage vs. live wagon capacity (wagonsFor), so the score
+   * is computed here — when doc review closes and the batch runs — and
+   * persisted so the priority board shows the same ranking. The pool arrives
+   * SQL-ordered by the old scores; the caller must re-sort after this.
+   */
+  private async recomputeBulkPriorities(
+    pool: Booking[],
+    wagonDims: WagonDims,
+  ): Promise<void> {
+    for (const booking of pool) {
+      if (booking.freightType !== 'BULK') continue;
+      try {
+        const wagons = this.wagonsFor(booking, wagonDims);
+        const score = await this.pricingService.computeSubmitPriorityScore(
+          booking,
+          wagons,
+        );
+        if (Number(booking.priorityScore ?? 0) === score) continue;
+        await this.dataSource
+          .getRepository(Booking)
+          .update(booking.id, { priorityScore: score });
+        booking.priorityScore = score;
+      } catch (err) {
+        // A failed recompute keeps the stored score — never blocks the batch.
+        this.logger.warn(
+          `Bulk priority recompute failed for ${booking.reference ?? booking.id}: ` +
+            `${(err as Error).message}`,
+        );
+      }
+    }
+  }
+
+  /** Restore the batch pool ordering (mirrors findBatchPool's ORDER BY) after scores changed. */
+  private resortPoolByPriority(pool: Booking[]): void {
+    pool.sort(
+      (a, b) =>
+        Number(b.isGovernment) - Number(a.isGovernment) ||
+        Number(b.priorityScore ?? 0) - Number(a.priorityScore ?? 0) ||
+        (a.fullyExecutedAt?.getTime() ?? Infinity) -
+          (b.fullyExecutedAt?.getTime() ?? Infinity) ||
+        a.createdAt.getTime() - b.createdAt.getTime(),
+    );
+  }
+
   /**
    * Wagons a booking occupies. Two axes bind independently and the booking needs
    * enough wagons to satisfy BOTH, so the count is the larger of:
@@ -2298,9 +2375,14 @@ export class BookingBatchService implements OnModuleInit {
    * That under-reported the board and let the fill loop overbook the train.
    */
   private wagonsFor(booking: Booking, wagonDims: WagonDims): number {
-    if (booking.wagonsRequired && booking.wagonsRequired > 0) {
-      return Math.ceil(booking.wagonsRequired);
-    }
+    // Stored wagonsRequired is a candidate, never an early return: rows written
+    // while sumWagonsRequired hardcoded BULK to 1 wagon are still in the DB, and
+    // trusting them charged one tare for a whole bulk consist (a 700T booking on
+    // 70T wagons read 700 + 1 tare instead of 700 + 10 tares).
+    const stored =
+      booking.wagonsRequired && booking.wagonsRequired > 0
+        ? Math.ceil(booking.wagonsRequired)
+        : 0;
 
     // TEU-aware: two 20ft share one wagon (wagonsPerUnit = 0.5). The old fallback
     // summed raw container QUANTITY, so 20×20ft counted as 20 wagons, not 10.
@@ -2311,7 +2393,7 @@ export class BookingBatchService implements OnModuleInit {
     const byWeight =
       cargoTons > 0 && capacityTons > 0 ? Math.ceil(cargoTons / capacityTons) : 0;
 
-    return Math.max(DEFAULT_WAGONS_PER_BOOKING, byLength, byWeight);
+    return Math.max(DEFAULT_WAGONS_PER_BOOKING, stored, byLength, byWeight);
   }
 
   private capacityFor(