From 3d8638eb077d320181d5e5c15558d6a0f375f201 Mon Sep 17 00:00:00 2001
From: O K <panariga@gmail.com>
Date: Mon, 8 Dec 2025 13:11:17 +0200
Subject: [PATCH] add NONSTANDARD handling

---
 usps_api_bridge.php | 72 +++++++++++++++++++++++++--------------------
 1 file changed, 40 insertions(+), 32 deletions(-)

diff --git a/usps_api_bridge.php b/usps_api_bridge.php
index e21ced9..46c4d6c 100644
--- a/usps_api_bridge.php
+++ b/usps_api_bridge.php
@@ -139,9 +139,6 @@ class Usps_Api_Bridge extends Module
         return $helper->generateForm([$fields_form]);
     }
 
-/**
-     * THE CORE BRIDGE LOGIC
-     */
     public function calculateRate($params, $shipping_cost, $products, $originalModule)
     {
         require_once(dirname(__FILE__) . '/classes/UspsV3Client.php');
@@ -152,26 +149,25 @@ class Usps_Api_Bridge extends Module
             return false;
         }
 
-        // 2. Identify which Service (Method) PrestaShop is asking for
+        // 2. Identify Service
         $carrierId = $params->id_carrier;
-        
         $sql = 'SELECT code FROM `' . _DB_PREFIX_ . 'uspsl_method` WHERE id_carrier = ' . (int)$carrierId;
         $methodCode = Db::getInstance()->getValue($sql);
 
         if (!$methodCode) {
-            return false; 
+            return false;
         }
 
         // 3. Map Old Code to New API Enum
         $newApiClass = $this->mapServiceCodeToApiClass($methodCode);
         if (!$newApiClass) {
-            $this->log("Mapping failed for code: " . $methodCode);
+            $this->log("Mapping failed for legacy code: " . $methodCode);
             return false;
         }
 
-        // 4. Pack the Products
+        // 4. Pack Products
         $packedBoxes = $originalModule->getHelper()->getCarrierHelper()->packProducts($products, $params->id);
-        
+
         if (empty($packedBoxes)) {
             $this->log("Box packer returned empty.");
             return false;
@@ -181,31 +177,36 @@ class Usps_Api_Bridge extends Module
         $client = new UspsV3Client($token, (bool)Configuration::get('USPS_BRIDGE_LIVE_MODE'));
         $totalPrice = 0;
 
-        // 6. Get Origin/Dest addresses
+        // 6. Address Data
         $originZip = $this->getOriginZip($originalModule);
         $destAddress = new Address($params->id_address_delivery);
-        
-        // Clean zip codes (USPS V3 expects 5 digits for domestic)
+
         $originZip = substr(preg_replace('/[^0-9]/', '', $originZip), 0, 5);
         $destZip = substr(preg_replace('/[^0-9]/', '', $destAddress->postcode), 0, 5);
-        
         $isInternational = ($destAddress->id_country != Country::getByIso('US'));
 
-        // 7. Loop through every box and get a rate
+        // 7. Loop through boxes
         foreach ($packedBoxes as $packedBox) {
-            
-            // BoxPacker uses Grams and Millimeters by default
-            // USPS requires Pounds and Inches
-            
-            // Weight: Grams -> Pounds
+
+            // Weight Conversion (Grams -> Pounds)
             $weightInLbs = $this->convertUnit($packedBox->getWeight(), 'g', 'lbs', 3);
 
-            // Dimensions: Millimeters -> Inches
-            $box = $packedBox->getBox(); 
+            // USPS requires minimum 0.001 lbs. 0 causes errors.
+            if ($weightInLbs <= 0) $weightInLbs = 0.1;
+
+            // Dimensions (mm -> Inches)
+            $box = $packedBox->getBox();
             $length = $this->convertUnit($box->getOuterLength(), 'mm', 'in', 2);
             $width = $this->convertUnit($box->getOuterWidth(), 'mm', 'in', 2);
             $height = $this->convertUnit($box->getOuterDepth(), 'mm', 'in', 2);
 
+            // Determine Processing Category (Crucial for V3 API)
+            // Machinable: Length <= 22", Width <= 18", Height <= 15", Weight >= 6oz (0.375lbs) and <= 25lbs
+            $category = 'MACHINABLE';
+            if ($length > 22 || $width > 18 || $height > 15 || $weightInLbs > 25 || $weightInLbs < 0.375) {
+                $category = 'NONSTANDARD';
+            }
+
             // Build Payload
             $payload = [
                 'originZIPCode' => $originZip,
@@ -216,40 +217,47 @@ class Usps_Api_Bridge extends Module
                 'mailClass' => $newApiClass,
                 'priceType' => 'COMMERCIAL',
                 'mailingDate' => date('Y-m-d', strtotime('+1 day')),
-                'processingCategory' => 'MACHINABLE',
-                'rateIndicator' => 'SP' 
+                'processingCategory' => $category,
+                'rateIndicator' => 'SP' // Single Piece
             ];
 
-            // -- HANDLE FLAT RATES --
-            $rateIndicator = $this->mapBoxToRateIndicator($box->getReference());
-            if ($rateIndicator) {
-                $payload['rateIndicator'] = $rateIndicator;
+            // Flat Rate Override
+            $flatRateIndicator = $this->mapBoxToRateIndicator($box->getReference());
+            if ($flatRateIndicator) {
+                $payload['rateIndicator'] = $flatRateIndicator;
+                // Dimensions technically ignored for Flat Rate, but required by API schema
+                // Processing category usually irrelevant for Flat Rate but must be valid Enum
             }
 
             if ($isInternational) {
                 $payload['destinationCountryCode'] = Country::getIsoById($destAddress->id_country);
                 $payload['originZIPCode'] = $originZip;
-                
+                // Remove domestic specific fields
+                unset($payload['destinationEntryFacilityType']);
+                unset($payload['destinationZIPCode']);
+
                 $response = $client->getInternationalRate($payload);
             } else {
                 $payload['destinationZIPCode'] = $destZip;
                 $payload['destinationEntryFacilityType'] = 'NONE';
-                
+
                 $response = $client->getDomesticRate($payload);
             }
 
-            // Process Response
+            // Log Payload on Error for Debugging
             if (isset($response['error'])) {
                 $this->log("API Error: " . $response['error']);
+                $this->log("Payload causing error: " . json_encode($payload));
                 return false;
             }
 
+            // Parse Price
             if (isset($response['totalBasePrice'])) {
                 $totalPrice += (float)$response['totalBasePrice'];
             } elseif (isset($response['rateOptions'][0]['totalBasePrice'])) {
                 $totalPrice += (float)$response['rateOptions'][0]['totalBasePrice'];
             } else {
-                $this->log("API Response missing price: " . print_r($response, true));
+                $this->log("API Response missing price. Full response: " . json_encode($response));
                 return false;
             }
         }
@@ -275,7 +283,7 @@ class Usps_Api_Bridge extends Module
 
         // Normalize to base unit (grams or mm)
         $baseValue = $value * (isset($units[$from]) ? $units[$from] : 1);
-        
+
         // Convert to target unit
         $converted = $baseValue / (isset($units[$to]) ? $units[$to] : 1);