edr-platform/apps/edr-freight-api/src/modules/train-scheduling/utils/wagon-plan.util.ts

import { AllocationLoadType } from '@edr/types';

import { Booking } from '../../bookings/entities/booking.entity';
import { containersPerWagonForSize, wagonsPerUnitForSize } from '../../rule-engine/container-type.util';
import { WagonType } from '../../wagon-types/entities/wagon-type.entity';
import {
  bookingCargoTons,
  bulkItemsFitFor,
  bulkItemWagonsRequired,
  bulkTonsPerWagonFor,
  bulkTonWagonsRequired,
  consistViolations,
} from '../train-capacity.util';

export const MAX_TRAIN_WEIGHT_TONS = 3500;
export const MAX_TRAIN_LENGTH_METERS = 760;
export const MAX_TEU_SLOTS_PER_WAGON = 2;

export type TrainLimitConfig = {
  maxWeightTons?: number;
  maxLengthMeters?: number;
  maxWagonsPerTrain?: number;
  max20ftPairWeightDiffTons?: number;
};

export type ContainerPlacementRules = {
  /**
   * Hard per-box weight ceiling keyed by booking container LINE id, resolved
   * from the rule engine's weight limit rule (`max_capacity_tons`) for the
   * line's container type and the booking's trade direction. A line with no
   * entry has no ceiling — the rule's capacity is optional.
   */
  maxContainerWeightTonsByLineId?: Record<string, number>;
  max20ftPairWeightDiffTons?: number;
};

export type WagonAllocationRecord = {
  bookingId: string;
  bookingReference: string;
  allocatedWeightTons: number;
  loadType: AllocationLoadType;
};

export type SlotLoadType = 'CONTAINER' | 'BULK';

export type WagonPlanSlot = {
  sequenceNo: number;
  wagonTypeId: string;
  wagonTypeCode: string;
  capacityTons: number;
  lengthMeters: number;
  /** Empty weight of this wagon — the locomotive pulls it whether or not it is loaded. */
  tareWeightTons: number;
  /** Cargo tons on this wagon. Gross weight = tareWeightTons + assignedWeightTons. */
  assignedWeightTons: number;
  allocations: WagonAllocationRecord[];
  slotLoadType?: SlotLoadType;
  /**
   * Leg occupancy for sub-corridor bookings (dynamic consist): the slot boards
   * at boardYardId and alights at alightYardId. Null = the schedule's own
   * endpoint (whole-route slot, legacy behavior).
   */
  boardYardId?: string | null;
  alightYardId?: string | null;
};

export type ContainerUnitRow = {
  bookingId: string;
  bookingReference: string;
  bookingContainerId: string;
  unitIndex: number;
  containerTypeId: string;
  containerTypeCode: string;
  label: string;
  grossWeightTons: number;
  sizeFt?: number;
  containersPerWagon?: number;
  teuSlots?: number;
  containerNumber?: string | null;
};

export type ContainerPlacementInput = {
  bookingContainerId: string;
  unitIndex: number;
  sequenceNo: number;
  containerId?: string;
  containerNumber?: string;
  sealNumber?: string;
};

export function roundTons(value: number | string | null | undefined): number {
  const numericValue = typeof value === 'number' ? value : Number(value ?? 0);
  if (!Number.isFinite(numericValue)) return 0;
  return Number(numericValue.toFixed(3));
}

/**
 * Tare of a wagon type. Nullable only on rows predating the NOT NULL backfill;
 * a missing tare must read as 0 rather than silently inventing dead weight.
 */
export function tareTonsOf(wagonType: Pick<WagonType, 'tareWeightTons'>): number {
  return roundTons(wagonType.tareWeightTons ?? 0);
}

/** TEU slots on a wagon: 40ft = 2, 20ft = 1 (max 2 TEU / wagon). */
export function teuSlotsForSizeFt(sizeFt: number): number {
  return sizeFt >= 40 ? 2 : 1;
}

type ContainerLine = {
  quantity?: number | null;
  wagonsRequired?: number | null;
  containerType?: { sizeFt?: number | null } | null;
};

/**
 * RAW (un-ceiled) wagon fraction one container line occupies: qty × size-derived
 * fraction (40ft = 1, 20ft = 0.5). Two 20ft = 1.0, three 20ft = 1.5. Kept
 * fractional so the BOOKING total is ceiled once — ceiling per line over-counts a
 * booking that splits its 20ft units across several lines (3×20 + 3×20 = 3
 * wagons, not 4).
 */
function lineWagonsRaw(line: ContainerLine): number {
  const qty = Number(line.quantity ?? 0);
  if (qty <= 0) return 0;
  const sizeFt = Number(line.containerType?.sizeFt);
  if (Number.isFinite(sizeFt) && sizeFt > 0) {
    return qty * wagonsPerUnitForSize(sizeFt);
  }
  // No size on the type: fall back to the line's stored fraction, else treat
  // the whole line as one wagon.
  const stored = Number(line.wagonsRequired);
  return Number.isFinite(stored) && stored > 0 ? stored : 1;
}

/**
 * Whole wagons a set of container lines needs: ceil the summed RAW fraction so a
 * half-full 20ft wagon rounds up ONCE at the booking level. Empty set → 0.
 */
export function containerWagonsForLines(lines: ContainerLine[]): number {
  const raw = lines.reduce((sum, line) => sum + lineWagonsRaw(line), 0);
  return raw > 0 ? Math.ceil(raw) : 0;
}

/**
 * Build slot-based wagon plan for CONTAINER bookings using booking_container.wagons_required.
 */
export function buildContainerWagonPlan(
  bookings: Booking[],
  wagonType: WagonType,
): WagonPlanSlot[] {
  // Whole wagons PER BOOKING (ceil each booking's total TEU once — a 20ft unit
  // can share a wagon with another 20ft of the SAME booking, never across
  // bookings), then sum. Ceiling per line instead would over-count a booking
  // that splits its 20ft units across several lines.
  const totalSlots = bookings.reduce((sum, booking) => {
    const bookingSlots = containerWagonsForLines(booking.bookingContainers ?? []);
    return sum + Math.max(bookingSlots, 1);
  }, 0);

  const slots = Math.max(1, totalSlots);
  const basePlan: WagonPlanSlot[] = Array.from({ length: slots }, (_, index) => ({
    sequenceNo: index + 1,
    wagonTypeId: wagonType.id,
    wagonTypeCode: wagonType.code,
    capacityTons: Number(wagonType.capacityTons),
    lengthMeters: Number(wagonType.lengthMeters),
    tareWeightTons: tareTonsOf(wagonType),
    assignedWeightTons: 0,
    allocations: [],
  }));

  return allocateContainersToSlots(bookings, basePlan).map((slot) => ({
    ...slot,
    slotLoadType: 'CONTAINER' as SlotLoadType,
  }));
}

/**
 * Build weight-based wagon plan for BULK bookings.
 */
export function buildBulkWagonPlan(
  bookings: Booking[],
  wagonType: WagonType,
): WagonPlanSlot[] {
  const capacity = Number(wagonType.capacityTons);
  // Break-bulk (PER_ITEM) bookings size by indivisible items per booking —
  // their tonnage must NOT pool with PER_TON cargo (an item can't split
  // across wagons the way loose tonnage can).
  const itemSlotsByBooking = bookings.map((b) =>
    // The plan fixed THIS wagon type, so its configured items-fit binds — not
    // the best fit across the cargo's allowed types.
    bulkItemWagonsRequired(b, capacity, bulkItemsFitFor(b.cargoType, wagonType.id)),
  );
  const itemSlots = itemSlotsByBooking.reduce((sum, n) => sum + n, 0);

  // PER_TON cargo with a per-wagon tonnage cap (sugar 50T on a 70T wagon) can't
  // pool with uncapped tonnage either: its wagons stop at the cap, so 200T needs
  // 4 wagons and pooling it at 70T would plan 3. Capped bookings are sized on
  // their own cap; only genuinely uncapped tonnage pools at rated capacity.
  // A NUMBER_OF_WAGONS booking is "capped" at its even share (tons ÷ requested),
  // so it plans exactly the requested count.
  const cappedTonSlotsByBooking = bookings.map((b, i) =>
    itemSlotsByBooking[i] > 0 ||
    bulkTonsPerWagonFor(b, b.cargoType, wagonType.id, capacity) >= capacity
      ? 0
      : bulkTonWagonsRequired(b, b.cargoType, wagonType.id, capacity),
  );
  const cappedTonSlots = cappedTonSlotsByBooking.reduce((sum, n) => sum + n, 0);

  // One bulk booking per wagon — bookings never pool tonnage on a shared
  // wagon, so each uncapped booking sizes its own wagons (ceil per booking,
  // not over the pooled total).
  const tonSlots = bookings.reduce((sum, b, i) => {
    if (itemSlotsByBooking[i] > 0 || cappedTonSlotsByBooking[i] > 0) return sum;
    const weight = roundTons(Number(b.cargoTotalWeightVgm ?? 0));
    return weight > 0 ? sum + Math.ceil(weight / capacity) : sum;
  }, 0);
  const slots = Math.max(1, tonSlots + itemSlots + cappedTonSlots);

  const basePlan: WagonPlanSlot[] = Array.from({ length: slots }, (_, index) => ({
    sequenceNo: index + 1,
    wagonTypeId: wagonType.id,
    wagonTypeCode: wagonType.code,
    capacityTons: capacity,
    lengthMeters: Number(wagonType.lengthMeters),
    tareWeightTons: tareTonsOf(wagonType),
    assignedWeightTons: 0,
    allocations: [],
  }));

  return allocateBookingsToSlots(bookings, basePlan, AllocationLoadType.Bulk).map((slot) => ({
    ...slot,
    slotLoadType: 'BULK' as SlotLoadType,
  }));
}

/**
 * Build a mixed consist: container slots first, then bulk slots, with unified sequence numbers.
 */
export function buildMixedWagonPlan(
  containerBookings: Booking[],
  bulkBookings: Booking[],
  containerWagonType: WagonType,
  bulkWagonType: WagonType,
): WagonPlanSlot[] {
  const containerPlan = containerBookings.length
    ? buildContainerWagonPlan(containerBookings, containerWagonType)
    : [];
  const bulkPlan = bulkBookings.length
    ? buildBulkWagonPlan(bulkBookings, bulkWagonType)
    : [];

  const tagged: WagonPlanSlot[] = [
    ...containerPlan.map((slot) => ({ ...slot, slotLoadType: 'CONTAINER' as SlotLoadType })),
    ...bulkPlan.map((slot) => ({ ...slot, slotLoadType: 'BULK' as SlotLoadType })),
  ];

  if (!tagged.length) {
    return [
      {
        sequenceNo: 1,
        wagonTypeId: containerWagonType.id,
        wagonTypeCode: containerWagonType.code,
        capacityTons: Number(containerWagonType.capacityTons),
        lengthMeters: Number(containerWagonType.lengthMeters),
        tareWeightTons: tareTonsOf(containerWagonType),
        assignedWeightTons: 0,
        allocations: [],
        slotLoadType: 'CONTAINER',
      },
    ];
  }

  return tagged.map((slot, index) => ({
    ...slot,
    sequenceNo: index + 1,
  }));
}

export function expandBookingContainerUnits(bookings: Booking[]): ContainerUnitRow[] {
  const rows: ContainerUnitRow[] = [];

  for (const booking of bookings.filter((b) => b.freightType === 'CONTAINER')) {
    for (const line of booking.bookingContainers ?? []) {
      const qty = Number(line.quantity ?? 0);
      const code = line.containerType?.code ?? line.containerType?.label ?? 'Container';
      const sizeFt = Number(line.containerType?.sizeFt ?? (code.includes('40') ? 40 : 20));
      const perWagon = containersPerWagonForSize(sizeFt);
      const teuSlots = teuSlotsForSizeFt(sizeFt);
      // The REAL per-container numbers/weights entered at booking time. Unit i of
      // the line maps to units[i] (sortOrder order); the line-level number is only
      // a legacy fallback — never invent numbers here.
      const units = [...(line.units ?? [])].sort(
        (a, b) => Number(a.sortOrder ?? 0) - Number(b.sortOrder ?? 0),
      );
      for (let i = 0; i < qty; i += 1) {
        const unit = units[i];
        rows.push({
          bookingId: booking.id,
          bookingReference: booking.reference,
          bookingContainerId: line.id,
          unitIndex: i,
          containerTypeId: line.containerTypeId ?? '',
          containerTypeCode: code,
          label: `${booking.reference} · ${i + 1}/${qty} · ${code}`,
          grossWeightTons: Number(unit?.vgmTons ?? line.vgmPerUnitTons),
          sizeFt,
          containersPerWagon: perWagon,
          teuSlots,
          containerNumber:
            unit?.containerNumber?.trim() || line.containerNumber || null,
        });
      }
    }
  }

  return rows;
}

export function getContainerSlotSequenceNos(wagonPlan: WagonPlanSlot[]): number[] {
  return wagonPlan
    .filter((slot) => slot.slotLoadType === 'CONTAINER' || slot.allocations.some(
      (a) => a.loadType === AllocationLoadType.Container,
    ))
    .map((slot) => slot.sequenceNo);
}

function allocateBookingsToSlots(
  bookings: Booking[],
  basePlan: WagonPlanSlot[],
  loadType: AllocationLoadType,
): WagonPlanSlot[] {
  const remaining = bookings.map((booking) => ({
    bookingId: booking.id,
    bookingReference: booking.reference,
    // bookingCargoTons, not the raw VGM column: for break-bulk (PER_ITEM)
    // bookings that column is an item COUNT, not tons.
    remainingWeightTons: roundTons(bookingCargoTons(booking)),
    cargoType: booking.cargoType,
    booking,
  }));

  let bookingIndex = 0;

  return basePlan.map((slot) => {
    let wagonRemaining = roundTons(slot.capacityTons);
    const allocations: WagonAllocationRecord[] = [];
    let assignedWeightTons = 0;

    while (wagonRemaining > 0 && bookingIndex < remaining.length) {
      const booking = remaining[bookingIndex];
      // A PER_TON loading cap (sugar 50T on a 70T wagon) binds the FILL as well
      // as the wagon count — the plan reserved a wagon per capped chunk, so
      // pouring rated capacity into it would leave the last wagon empty. A
      // NUMBER_OF_WAGONS booking fills each wagon its even share (tons ÷
      // requested) for the same reason.
      const takeCap = Math.min(
        wagonRemaining,
        bulkTonsPerWagonFor(
          booking.booking,
          booking.cargoType,
          slot.wagonTypeId,
          slot.capacityTons,
        ),
      );
      const allocatedWeightTons = roundTons(
        Math.min(takeCap, booking.remainingWeightTons),
      );

      if (allocatedWeightTons <= 0) {
        bookingIndex += 1;
        continue;
      }

      allocations.push({
        bookingId: booking.bookingId,
        bookingReference: booking.bookingReference,
        allocatedWeightTons,
        loadType,
      });

      booking.remainingWeightTons = roundTons(
        booking.remainingWeightTons - allocatedWeightTons,
      );
      wagonRemaining = roundTons(wagonRemaining - allocatedWeightTons);
      assignedWeightTons = roundTons(assignedWeightTons + allocatedWeightTons);

      if (booking.remainingWeightTons <= 0) {
        bookingIndex += 1;
      }
      // One bulk booking per wagon: a wagon carrying bulk takes nothing else —
      // never a second booking's cargo. `buildBulkWagonPlan` sized the slots
      // per booking, so leftover room on this wagon is not free capacity.
      // Close the wagon after its single allocation.
      break;
    }

    return { ...slot, assignedWeightTons, allocations };
  });
}

/**
 * Allocate container bookings across wagon slots by TEU capacity. A wagon holds at most
 * 2 TEU, so it carries either one 40ft container (2 TEU) or two 20ft containers (1 TEU
 * each) — a 40ft is NEVER mixed onto the same wagon as a 20ft. Every physical container
 * maps to a real wagon allocation, and this mirrors the frontend auto-fill packing
 * exactly so a placement's sequenceNo always lands on a slot that holds an allocation
 * for its booking.
 *
 * Weight-based packing (allocateBookingsToSlots) is wrong for containers: it collapses
 * several light containers into the first wagons by tonnage and leaves later container
 * units without an allocation slot, which silently drops their container items on assign.
 */
function allocateContainersToSlots(
  bookings: Booking[],
  basePlan: WagonPlanSlot[],
): WagonPlanSlot[] {
  const slots = basePlan.map((slot) => ({
    ...slot,
    assignedWeightTons: 0,
    allocations: [] as WagonAllocationRecord[],
  }));
  if (!slots.length) return slots;

  const units = expandBookingContainerUnits(bookings);
  let currentSlotIndex = 0;
  let teuInCurrentSlot = 0;

  for (const unit of units) {
    const teu = unit.teuSlots ?? teuSlotsForSizeFt(unit.sizeFt ?? 20);

    // Move to the next wagon once this one can't fit the container's TEU. This keeps a
    // 40ft (2 TEU) alone on its wagon and never pairs it with a 20ft.
    if (teuInCurrentSlot > 0 && teuInCurrentSlot + teu > MAX_TEU_SLOTS_PER_WAGON) {
      currentSlotIndex += 1;
      teuInCurrentSlot = 0;
    }

    const slot = slots[Math.min(currentSlotIndex, slots.length - 1)]!;

    let allocation = slot.allocations.find((a) => a.bookingId === unit.bookingId);
    if (!allocation) {
      allocation = {
        bookingId: unit.bookingId,
        bookingReference: unit.bookingReference,
        allocatedWeightTons: 0,
        loadType: AllocationLoadType.Container,
      };
      slot.allocations.push(allocation);
    }
    allocation.allocatedWeightTons = roundTons(
      allocation.allocatedWeightTons + unit.grossWeightTons,
    );
    slot.assignedWeightTons = roundTons(slot.assignedWeightTons + unit.grossWeightTons);
    teuInCurrentSlot += teu;
  }

  return slots;
}

export function expandContainerItems(
  booking: Booking,
  allocationId: string,
): Array<{
  wagonBookingAllocationId: string;
  bookingContainerId: string;
  containerTypeId: string;
  grossWeightTons: number;
  positionOnWagon: number | null;
}> {
  const items: Array<{
    wagonBookingAllocationId: string;
    bookingContainerId: string;
    containerTypeId: string;
    grossWeightTons: number;
    positionOnWagon: number | null;
  }> = [];

  for (const line of booking.bookingContainers ?? []) {
    const qty = Number(line.quantity ?? 0);
    for (let i = 0; i < qty; i += 1) {
      items.push({
        wagonBookingAllocationId: allocationId,
        bookingContainerId: line.id,
        containerTypeId: line.containerTypeId ?? '',
        grossWeightTons: Number(line.vgmPerUnitTons),
        positionOnWagon: qty > 1 ? i + 1 : null,
      });
    }
  }

  return items;
}

/**
 * Wagons a booking actually occupies. Prefer counting the built wagon plan's
 * slots that carry one of the booking's allocations — for BULK that is its
 * tonnage spread over real wagons (a 700T booking on 70T wagons rides 10
 * wagons, and downstream gross-weight math charges 10 tares, not 1). Without
 * a plan there is no capacity to divide by, so fall back to the pre-plan
 * estimates: 1 for bulk, the lines' stored counts for containers.
 */
export function sumWagonsRequired(booking: Booking, wagonPlan?: WagonPlanSlot[]): number {
  const occupiedSlots = (wagonPlan ?? []).filter((slot) =>
    slot.allocations.some((allocation) => allocation.bookingId === booking.id),
  ).length;
  if (occupiedSlots > 0) {
    return occupiedSlots;
  }
  if (booking.freightType === 'BULK') {
    return 1;
  }
  return (booking.bookingContainers ?? []).reduce(
    (sum, line) => sum + Number(line.wagonsRequired ?? 0),
    0,
  );
}

/**
 * One wagon carries one kind of cargo AT A TIME: while a bulk load rides, the
 * wagon holds nothing else — no container beside it and no second bulk
 * booking. Container allocations may share a wagon with each other (TEU rules
 * apply).
 *
 * "At a time" is the whole rule: a wagon whose cargo alights at Dire Dawa is
 * empty steel for whatever boards there, so an import container on
 * Doraleh→Dire and bulk on Dire→Kality legitimately share one wagon. Pass
 * `legs` (booking id → stop-index span) to check per corridor edge; without
 * it every allocation is treated as riding the whole route, which is the
 * correct reading for a single-leg train.
 */
export function validateWagonCargoExclusivity(
  wagonPlan: WagonPlanSlot[],
  legs?: Map<string, { from: number; to: number }>,
  edgeCount = 1,
): string[] {
  const violations: string[] = [];
  const edges = Math.max(1, edgeCount);
  const spanOf = (bookingId: string) => {
    const leg = legs?.get(bookingId);
    if (!leg || leg.from < 0 || leg.to > edges || leg.from >= leg.to) {
      return { from: 0, to: edges };
    }
    return leg;
  };

  for (const slot of wagonPlan) {
    if (slot.allocations.length < 2) continue;
    // Per edge: who is on this wagon while it rides that edge?
    for (let edge = 0; edge < edges; edge += 1) {
      const riding = slot.allocations.filter((a) => {
        const span = spanOf(a.bookingId);
        return span.from <= edge && edge < span.to;
      });
      if (riding.length < 2) continue;
      if (riding.some((a) => a.loadType === AllocationLoadType.Bulk)) {
        violations.push(
          `Wagon #${slot.sequenceNo} mixes bulk with other cargo — a wagon carrying bulk takes that one load only`,
        );
        break;
      }
    }
  }
  return violations;
}

export function validateBulkWagonSlotWeights(wagonPlan: WagonPlanSlot[]): string[] {
  const violations: string[] = [];
  for (const slot of wagonPlan.filter((s) => s.slotLoadType === 'BULK')) {
    if (slot.assignedWeightTons > slot.capacityTons) {
      violations.push(
        `Bulk wagon #${slot.sequenceNo} load ${slot.assignedWeightTons}T exceeds capacity ${slot.capacityTons}T`,
      );
    }
  }
  return violations;
}

/**
 * Check a consist against its train's three limits. Weight is GROSS — every slot
 * contributes its own tare plus the cargo assigned to it — because the locomotive
 * pull limit governs what it drags, not what was sold. Length and tare are summed
 * per slot, so a mixed consist is measured as it actually stands rather than
 * through one representative wagon type.
 *
 * `wagonType` only supplies the fallback wagon count when `limits.maxWagonsPerTrain`
 * is absent; slot dimensions always win over it.
 */
export function validateTrainLimits(
  wagonPlan: WagonPlanSlot[],
  wagonType: Pick<WagonType, 'lengthMeters'>,
  limits?: TrainLimitConfig,
  /** Leg-aware cargo exclusivity — see {@link validateWagonCargoExclusivity}. */
  legs?: Map<string, { from: number; to: number }>,
  edgeCount?: number,
): string[] {
  const maxWeightTons = limits?.maxWeightTons ?? MAX_TRAIN_WEIGHT_TONS;
  const maxLengthMeters = limits?.maxLengthMeters ?? MAX_TRAIN_LENGTH_METERS;
  const wagonLength = Number(wagonType.lengthMeters) || 14;
  const maxWagonSlots =
    limits?.maxWagonsPerTrain ?? Math.floor(maxLengthMeters / wagonLength);

  const violations = consistViolations(
    wagonPlan.map((slot) => ({
      lengthMeters: Number(slot.lengthMeters),
      tareWeightTons: Number(slot.tareWeightTons ?? 0),
      cargoTons: Number(slot.assignedWeightTons),
    })),
    { maxWeightTons, maxLengthMeters, maxWagonSlots },
  );

  violations.push(...validateBulkWagonSlotWeights(wagonPlan));
  violations.push(...validateWagonCargoExclusivity(wagonPlan, legs, edgeCount));

  return violations;
}

/**
 * Mixed consist: the wagon-count fallback uses the shortest type present, since
 * that is the most wagons that could ever fit. Weight and length still come from
 * the slots themselves.
 */
export function validateMixedTrainLimits(
  wagonPlan: WagonPlanSlot[],
  wagonTypes: Array<Pick<WagonType, 'lengthMeters'>>,
  limits?: TrainLimitConfig,
  legs?: Map<string, { from: number; to: number }>,
  edgeCount?: number,
): string[] {
  const maxLengthMeters = limits?.maxLengthMeters ?? MAX_TRAIN_LENGTH_METERS;
  const minWagonLength = Math.min(
    ...wagonTypes.map((wt) => Number(wt.lengthMeters) || 14),
    14,
  );
  const maxWagonsPerTrain =
    limits?.maxWagonsPerTrain ?? Math.floor(maxLengthMeters / minWagonLength);

  return validateTrainLimits(
    wagonPlan,
    { lengthMeters: minWagonLength },
    { ...limits, maxWagonsPerTrain },
    legs,
    edgeCount,
  );
}

/**
 * Leg-aware limit check: with a real stop list, a slot only counts on the
 * edges it actually rides (boardYardId→alightYardId; null = the schedule's
 * own endpoint). Each edge is validated as its own consist, so an intercity
 * wagon on Gelan→Adama never counts against a train that is full only on
 * Adama→Doraleh. Two stops (or fewer) degrade to the whole-train check.
 */
export function validateMixedTrainLimitsPerEdge(
  wagonPlan: WagonPlanSlot[],
  wagonTypes: Array<Pick<WagonType, 'lengthMeters'>>,
  limits: TrainLimitConfig | undefined,
  stops: string[],
  /** Display names parallel to `stops` — violations then name the leg they hit. */
  stopLabels?: string[],
  /** Booking id → stop-index span, so cargo exclusivity is judged per edge. */
  legs?: Map<string, { from: number; to: number }>,
): string[] {
  const edges = Math.max(1, stops.length - 1);
  if (stops.length <= 2) {
    return validateMixedTrainLimits(wagonPlan, wagonTypes, limits, legs, edges);
  }
  const spans = slotSpans(wagonPlan, stops);
  const label = (i: number) => stopLabels?.[i] ?? stops[i];
  const violations = new Set<string>();
  for (let edge = 0; edge < stops.length - 1; edge += 1) {
    // A shared slot rides the UNION of its cargo legs, but only carries each
    // booking's cargo on that booking's own edges — weigh the edge with the
    // cargo actually aboard there, not the slot's whole-route scalar, or a
    // container boarding at Dire Dawa reads as hauled from Djibouti.
    const active = wagonPlan
      .filter((_, i) => spans[i].from <= edge && edge < spans[i].to)
      .map((slot) => ({
        ...slot,
        assignedWeightTons: slotCargoOnEdge(slot, edge, edges, legs),
      }));
    if (!active.length) continue;
    for (const violation of validateMixedTrainLimits(
      active,
      wagonTypes,
      limits,
      legs,
      edges,
    )) {
      violations.add(`Leg ${label(edge)} → ${label(edge + 1)}: ${violation}`);
    }
  }
  return [...violations];
}

/**
 * The slot fields per-edge usage math actually reads — lets callers feed
 * persisted TrainSetWagon rows (or any structural subset), not only plan slots.
 */
export type EdgeUsageSlot = Pick<
  WagonPlanSlot,
  'lengthMeters' | 'tareWeightTons' | 'assignedWeightTons'
> & {
  boardYardId?: string | null;
  alightYardId?: string | null;
  allocations?: unknown[];
};

/**
 * Cargo tons a slot actually carries on one edge. With a legs map and readable
 * allocation records, each booking's cargo counts only on the edges that
 * booking rides (an unmapped booking stays on the slot's whole span). Without
 * either — or when any allocation lacks a numeric weight, e.g. persisted rows
 * fed through {@link EdgeUsageSlot} — falls back to the slot's whole-span
 * `assignedWeightTons`, the pre-existing reading.
 */
function slotCargoOnEdge(
  slot: EdgeUsageSlot,
  edge: number,
  edgeCount: number,
  legs?: Map<string, { from: number; to: number }>,
): number {
  const wholeSpanCargo = Number(slot.assignedWeightTons ?? 0);
  const allocations = (slot.allocations ?? []) as Array<{
    bookingId?: string;
    allocatedWeightTons?: number | string;
  }>;
  if (!legs?.size || !allocations.length) return wholeSpanCargo;
  let cargo = 0;
  for (const allocation of allocations) {
    const weight = Number(allocation?.allocatedWeightTons);
    if (!Number.isFinite(weight)) return wholeSpanCargo;
    const leg = allocation.bookingId ? legs.get(allocation.bookingId) : undefined;
    const rides =
      !leg || leg.from < 0 || leg.to > edgeCount || leg.from >= leg.to
        ? true
        : leg.from <= edge && edge < leg.to;
    if (rides) cargo += weight;
  }
  return cargo;
}

/** Per-slot stop-index spans; a yard missing from the stop list keeps the slot on the whole route. */
function slotSpans(
  wagonPlan: EdgeUsageSlot[],
  stops: string[],
): Array<{ from: number; to: number }> {
  const lastIdx = stops.length - 1;
  return wagonPlan.map((slot) => {
    const from = slot.boardYardId ? stops.indexOf(slot.boardYardId) : 0;
    const to = slot.alightYardId ? stops.indexOf(slot.alightYardId) : lastIdx;
    return { from: from >= 0 ? from : 0, to: to > 0 ? to : lastIdx };
  });
}

/**
 * The corridor's binding edge: gross tons (tare + assigned cargo) and length
 * summed over only the slots riding each edge, maxed across edges. This is the
 * figure a locomotive pull/length limit must be compared against — a train is
 * never heavier than its heaviest single leg, so summing disjoint legs
 * (intercity Gelan→Adama + export Adama→Doraleh) over-reports the train.
 * Two stops or fewer degrade to the whole-train totals.
 */
export function maxEdgeConsistUsage(
  wagonPlan: EdgeUsageSlot[],
  stops: string[],
  /** Booking id → stop-index span; cargo then weighs only its own edges. */
  legs?: Map<string, { from: number; to: number }>,
): { grossWeightTons: number; lengthMeters: number; loadedWagonCount: number } {
  return perEdgeConsistUsage(wagonPlan, stops, legs).reduce(
    (max, e) => ({
      grossWeightTons: Math.max(max.grossWeightTons, e.grossWeightTons),
      lengthMeters: Math.max(max.lengthMeters, e.lengthMeters),
      loadedWagonCount: Math.max(max.loadedWagonCount, e.loadedWagonCount),
    }),
    { grossWeightTons: 0, lengthMeters: 0, loadedWagonCount: 0 },
  );
}

/** Usage of one corridor edge (between stops[edge] and stops[edge + 1]). */
export type EdgeConsistUsage = {
  edge: number;
  grossWeightTons: number;
  lengthMeters: number;
  loadedWagonCount: number;
  wagonCount: number;
};

/**
 * Per-edge breakdown behind {@link maxEdgeConsistUsage}: every edge's own
 * consist totals, so callers can name WHICH leg breaks a limit instead of
 * only reporting the heaviest figure. Two stops or fewer collapse to a
 * single whole-route edge.
 */
export function perEdgeConsistUsage(
  wagonPlan: EdgeUsageSlot[],
  stops: string[],
  /**
   * Booking id → stop-index span. When given, a shared slot's cargo weighs
   * only the edges its booking rides (tare still rides the slot's whole
   * span) — without it a slot's full cargo counts on every edge it spans.
   */
  legs?: Map<string, { from: number; to: number }>,
): EdgeConsistUsage[] {
  const edgeCount = Math.max(1, stops.length - 1);
  const totals = (edge: number, slots: EdgeUsageSlot[]): EdgeConsistUsage => ({
    edge,
    grossWeightTons: slots.reduce(
      (sum, w) =>
        sum + Number(w.tareWeightTons ?? 0) + slotCargoOnEdge(w, edge, edgeCount, legs),
      0,
    ),
    lengthMeters: slots.reduce((sum, w) => sum + Number(w.lengthMeters ?? 0), 0),
    loadedWagonCount: slots.filter((w) => (w.allocations?.length ?? 1) > 0).length,
    wagonCount: slots.length,
  });
  if (stops.length <= 2) return [totals(0, wagonPlan)];
  const spans = slotSpans(wagonPlan, stops);
  return Array.from({ length: stops.length - 1 }, (_, edge) =>
    totals(
      edge,
      wagonPlan.filter((_, i) => spans[i].from <= edge && edge < spans[i].to),
    ),
  );
}

/**
 * Per-box weight rules for a container plan:
 *  - every unit is checked against its line's weight-limit-rule capacity
 *    ceiling (`maxContainerWeightTonsByLineId`, any size);
 *  - 20ft pairs sharing a wagon are checked for weight imbalance.
 */
export function validate20ftContainerRules(
  units: ContainerUnitRow[],
  placements: ContainerPlacementInput[],
  rules?: ContainerPlacementRules,
): string[] {
  const violations: string[] = [];
  const capacityByLine = rules?.maxContainerWeightTonsByLineId;
  const maxDiff = rules?.max20ftPairWeightDiffTons;
  if (capacityByLine == null && maxDiff == null) return violations;

  const placementByUnit = new Map(
    placements.map((p) => [`${p.bookingContainerId}:${p.unitIndex}`, p]),
  );

  const weightsBySlot = new Map<number, number[]>();

  for (const unit of units) {
    const maxEach = capacityByLine?.[unit.bookingContainerId];
    if (maxEach != null && unit.grossWeightTons > maxEach) {
      violations.push(
        `${unit.label} weight ${unit.grossWeightTons}T exceeds the weight limit rule capacity of ${maxEach}T for ${unit.containerTypeCode} containers`,
      );
    }

    const sizeFt = unit.sizeFt ?? (unit.containerTypeCode.includes('40') ? 40 : 20);
    if (sizeFt >= 40) continue;

    const placement = placementByUnit.get(`${unit.bookingContainerId}:${unit.unitIndex}`);
    if (!placement?.sequenceNo) continue;

    const list = weightsBySlot.get(placement.sequenceNo) ?? [];
    list.push(unit.grossWeightTons);
    weightsBySlot.set(placement.sequenceNo, list);
  }

  if (maxDiff != null) {
    for (const [sequenceNo, weights] of weightsBySlot.entries()) {
      if (weights.length < 2) continue;
      const diff = Math.abs(weights[0]! - weights[1]!);
      if (diff > maxDiff) {
        violations.push(
          `Wagon #${sequenceNo} 20ft pair weight difference ${roundTons(diff)}T exceeds max ${maxDiff}T`,
        );
      }
    }
  }

  return violations;
}

export function validateContainerPlacements(
  containerBookings: Booking[],
  wagonPlan: WagonPlanSlot[],
  placements: ContainerPlacementInput[],
  rules?: ContainerPlacementRules,
  /**
   * Leg-aware occupancy (cross-leg TEU sharing): booking id → stop-index leg.
   * With legs, a wagon's TEU/weight caps hold PER CORRIDOR EDGE — an intercity
   * 20ft and an export 20ft coexist on one wagon when their edges allow it.
   * Omitted → one edge, byte-identical to the whole-route check.
   */
  legs?: Map<string, { from: number; to: number }>,
  edgeCount?: number,
): string[] {
  const violations: string[] = [];
  const units = expandBookingContainerUnits(containerBookings);
  if (!units.length) return violations;

  const containerSlots = new Set(getContainerSlotSequenceNos(wagonPlan));
  const unitKeys = new Set(units.map((u) => `${u.bookingContainerId}:${u.unitIndex}`));
  const placementKeys = new Set<string>();
  const containerNumbers = new Set<string>();

  if (!placements.length) {
    violations.push('Container placements are required for container bookings');
    return violations;
  }

  for (const placement of placements) {
    const unitKey = `${placement.bookingContainerId}:${placement.unitIndex}`;
    if (!unitKeys.has(unitKey)) {
      violations.push(
        `Unknown container unit ${placement.bookingContainerId}#${placement.unitIndex}`,
      );
      continue;
    }
    if (placementKeys.has(unitKey)) {
      violations.push(`Duplicate placement for container unit ${unitKey}`);
    }
    placementKeys.add(unitKey);

    if (!containerSlots.has(placement.sequenceNo)) {
      violations.push(`Slot #${placement.sequenceNo} is not a container wagon slot`);
    }

    const hasInventory = Boolean(placement.containerId);
    const hasManual = Boolean(placement.containerNumber?.trim());
    if (!hasInventory && !hasManual) {
      violations.push(
        `Container unit ${unitKey} requires an existing container or a new container number`,
      );
    }

    if (hasManual) {
      const normalized = placement.containerNumber!.trim().toUpperCase();
      if (containerNumbers.has(normalized)) {
        violations.push(`Duplicate container number ${normalized}`);
      }
      containerNumbers.add(normalized);
    }
  }

  for (const unit of units) {
    const unitKey = `${unit.bookingContainerId}:${unit.unitIndex}`;
    if (!placementKeys.has(unitKey)) {
      violations.push(`Missing placement for ${unit.label}`);
    }
  }

  // TEU and weight are tracked PER EDGE of a unit's leg; without legs there is
  // a single edge and this is exactly the old whole-route accounting.
  const edges = Math.max(1, edgeCount ?? 1);
  const legOf = (bookingId: string): { from: number; to: number } => {
    const leg = legs?.get(bookingId);
    if (!leg || leg.from < 0 || leg.to > edges || leg.from >= leg.to) {
      return { from: 0, to: edges };
    }
    return leg;
  };
  const slotTeuUsed = new Map<number, number[]>();
  const slotWeightUsed = new Map<number, number[]>();
  const slotBySeq = new Map(wagonPlan.map((s) => [s.sequenceNo, s]));

  for (const placement of placements) {
    const unit = units.find(
      (u) =>
        u.bookingContainerId === placement.bookingContainerId &&
        u.unitIndex === placement.unitIndex,
    );
    if (!unit) continue;

    const teu = unit.teuSlots ?? teuSlotsForSizeFt(unit.sizeFt ?? 20);
    const leg = legOf(unit.bookingId);
    const teuRow =
      slotTeuUsed.get(placement.sequenceNo) ?? new Array<number>(edges).fill(0);
    let teuFits = true;
    for (let e = leg.from; e < leg.to; e += 1) {
      if ((teuRow[e] ?? 0) + teu > MAX_TEU_SLOTS_PER_WAGON) {
        teuFits = false;
        break;
      }
    }
    if (!teuFits) {
      violations.push(
        `Wagon #${placement.sequenceNo} cannot fit another ${unit.containerTypeCode} (max 1×40ft or 2×20ft per wagon)`,
      );
    } else {
      for (let e = leg.from; e < leg.to; e += 1) teuRow[e] = (teuRow[e] ?? 0) + teu;
      slotTeuUsed.set(placement.sequenceNo, teuRow);
    }

    const slot = slotBySeq.get(placement.sequenceNo);
    if (slot) {
      const weightRow =
        slotWeightUsed.get(placement.sequenceNo) ?? new Array<number>(edges).fill(0);
      let heaviestEdge = 0;
      for (let e = leg.from; e < leg.to; e += 1) {
        weightRow[e] = roundTons((weightRow[e] ?? 0) + unit.grossWeightTons);
        heaviestEdge = Math.max(heaviestEdge, weightRow[e]);
      }
      slotWeightUsed.set(placement.sequenceNo, weightRow);
      if (heaviestEdge > slot.capacityTons) {
        violations.push(
          `Wagon #${placement.sequenceNo} total container weight ${heaviestEdge}T exceeds capacity ${slot.capacityTons}T`,
        );
      }
    }
  }

  violations.push(...validate20ftContainerRules(units, placements, rules));

  return violations;
}