app.py

import os
import cv2
import base64
import json
import pandas as pd
import gradio as gr
import numpy as np
from roboflow import Roboflow
from openai import OpenAI
import re

# ================= CONFIG =================
ROBOFLOW_API_KEY = "uP19IAi98TqwLvHmNB8V"
ROBOFLOW_PROJECT = "terminal-block-jtgsl"
ROBOFLOW_VERSION = 1
CONF_THRESHOLD = 0.30
IOU_THRESHOLD = 0.4
TERMINAL_JSON_PATH = "terminal.json"

client = OpenAI(api_key=os.getenv("OPENAI_API_KEY"))
rf = Roboflow(api_key=ROBOFLOW_API_KEY)
model = rf.workspace().project(ROBOFLOW_PROJECT).version(ROBOFLOW_VERSION).model

# ================= LOAD REFERENCE =================
def load_terminal_reference():
    if not os.path.exists(TERMINAL_JSON_PATH): return {}
    try:
        with open(TERMINAL_JSON_PATH, "r") as f:
            data = json.load(f)
            return {str(i["terminal"]).strip().upper(): str(i["wire"]).strip().upper()
                    for i in data.get("terminal_blocks", []) if i.get("wire")}
    except: return {}

terminal_reference = load_terminal_reference()

def clean_terminal(text):
    text = re.sub(r'[^0-9]', '', text)
    return text

def clean_wire(text):
    text = text.upper().replace(" ", "")
    
    # Fix common OCR mistakes
    text = text.replace("O", "0")
    text = text.replace("I", "1")

    text = re.sub(r'[^A-Z0-9]', '', text)
    return text

def is_valid_wire(wire):
    return bool(re.match(r'^[A-Z]{1,3}[0-9]{2,4}[A-Z]{0,2}$', wire))

def validate_and_fix(t, w):
    t = clean_terminal(t)
    w = clean_wire(w)

    if not t:
        return None, None

    if w in ["", "NONE", "N/A"]:
        w = terminal_reference.get(t, "NONE")

    if not is_valid_wire(w):
        if t in terminal_reference:
            w = terminal_reference[t]

    return t, w
# ================= IMPROVED PREPROCESSING =================
def prepare_for_roboflow(img, max_side=1600):
    h, w = img.shape[:2]
    scale = min(max_side / max(h, w), 1)
    return cv2.resize(img, (int(w * scale), int(h * scale))) if scale < 1 else img

def upscale(img):
    if img.size == 0: return img
    # High-quality upscale to prevent "11" from blurring into "1"
    h, w = img.shape[:2]
    scale = 800 / h if h < 800 else 1.0
    return cv2.resize(img, None, fx=scale, fy=scale, interpolation=cv2.INTER_LANCZOS4)

def enhance_variants(img):
    variants = []
    if img.size == 0: return variants
   
    # Variant 1: Original
    variants.append(img)
   
    # Variant 2: Contrast Enhancement
    gray = cv2.cvtColor(img, cv2.COLOR_BGR2GRAY)
    clahe = cv2.createCLAHE(clipLimit=4.0, tileGridSize=(12, 12))
    enhanced_gray = clahe.apply(gray)
   
    # Variant 3: Denoised & Sharpened (Crucial for thin characters)
    denoised = cv2.fastNlMeansDenoising(enhanced_gray, None, 10, 7, 21)
    kernel = np.array([[0, -1, 0], [-1, 5, -1], [0, -1, 0]])
    sharpened = cv2.filter2D(denoised, -1, kernel)
    variants.append(cv2.cvtColor(sharpened, cv2.COLOR_GRAY2BGR))
   
    return variants

def img_to_base64(img):
    _, buffer = cv2.imencode(".jpg", img, [int(cv2.IMWRITE_JPEG_QUALITY), 95])
    return base64.b64encode(buffer).decode()

# ================= PIPELINE LOGIC =================
def verify(terminal, wire):
    t, w = terminal.strip().upper(), wire.strip().upper()
    if t not in terminal_reference: return "UNKNOWN"
    ref = terminal_reference[t]
    if w in ["NONE", "EMPTY", "N/A", ""]:
        return "MATCH" if ref == "NONE" else f"MISSING (Exp {ref})"
    return "MATCH" if ref == w else f"MISMATCH (Exp {ref})"

def fix_missing_wire(terminal, wire):
    terminal = terminal.strip().upper()
    wire = wire.strip().upper()

    # If OCR failed but reference exists → use reference
    if wire in ["NONE", "", "N/A"]:
        if terminal in terminal_reference:
            return terminal_reference[terminal]

    return wire

def group_by_columns(detections, threshold=30):
    detections = sorted(detections, key=lambda x: x["center"][0])
    columns = []

    for det in detections:
        placed = False
        for col in columns:
            if abs(col[0]["center"][0] - det["center"][0]) < threshold:
                col.append(det)
                placed = True
                break
        if not placed:
            columns.append([det])

    return columns


def run_pipeline(image):
    if image is None:
        return None, pd.DataFrame()

    img = prepare_for_roboflow(image)
    H, W = img.shape[:2]

    # ================= DETECTION =================
    preds = model.predict(img, confidence=int(CONF_THRESHOLD * 100)).json()["predictions"]

    wires, t_nums, w_nums, terms = [], [], [], []

    for p in preds:
        x, y, w, h = map(int, [p["x"], p["y"], p["width"], p["height"]])

        det = {
            "class": p["class"],
            "bbox": (
                max(0, x - w // 2),
                max(0, y - h // 2),
                min(W, x + w // 2),
                min(H, y + h // 2)
            ),
            "center": (x, y)
        }

        if p["class"] == "Wire":
            wires.append(det)
        elif p["class"] == "Terminal Number":
            t_nums.append(det)
        elif p["class"] == "Wire Number":
            w_nums.append(det)
        elif p["class"] == "Terminal":
            terms.append(det)

    # ================= 🔥 NEW COLUMN GROUPING =================
    columns = group_by_columns(t_nums + w_nums + terms, threshold=30)

    ocr_regions = []

    for i, col in enumerate(columns):
        x1 = min(d["bbox"][0] for d in col)
        y1 = min(d["bbox"][1] for d in col)
        x2 = max(d["bbox"][2] for d in col)
        y2 = max(d["bbox"][3] for d in col)

        pad = 10

        ocr_regions.append({
            "union_bbox": (
                max(0, x1 - pad),
                max(0, y1 - pad),
                min(W, x2 + pad),
                min(H, y2 + pad)
            ),
            "id": i
        })

    # ================= GPT PROMPT =================
    content = [{
        "type": "text",
        "text": """
STRICT RULES:
- One ID = one vertical column
- Terminal = number below screws
- Wire = text on white sleeve (ILxxx)
- NEVER merge columns
- NEVER skip digits
- If unclear return NONE

Output STRICT JSON:
[{"id":0,"terminal":"77","wire":"IL23CA"}]
"""
    }]

    # ================= IMAGE PREP =================
    for region in ocr_regions:
        x1, y1, x2, y2 = region["union_bbox"]

        roi = img[y1:y2, x1:x2]
        roi = upscale(roi)

        content.append({"type": "text", "text": f"id:{region['id']}"})

        for v in enhance_variants(roi):
            content.append({
                "type": "image_url",
                "image_url": {"url": f"data:image/jpeg;base64,{img_to_base64(v)}"}
            })

    results = []

    # ================= GPT OCR =================
    try:
        response = client.chat.completions.create(
            model="gpt-4o",
            messages=[{"role": "user", "content": content}],
            temperature=0
        )

        res_text = response.choices[0].message.content
        match = re.search(r'\[.*\]', res_text, re.DOTALL)

        if match:
            parsed = json.loads(match.group())

            for item in parsed:
                idx = item.get("id")

                if idx is not None and idx < len(ocr_regions):
                    t = str(item.get("terminal", "")).strip()
                    w = str(item.get("wire", "")).strip()

                    t, w = validate_and_fix(t, w)
                    w = fix_missing_wire(t, w)

                    results.append({
                        "Terminal": t,
                        "Wire": w,
                        "Verification": verify(t, w),
                        "bbox": ocr_regions[idx]["union_bbox"]
                    })

    except Exception as e:
        print(f"Error: {e}")

    # ================= SORT =================
    def safe_int(x):
        digits = ''.join(filter(str.isdigit, x))
        return int(digits) if digits else 999

    results = sorted(results, key=lambda x: safe_int(x["Terminal"]))

    # ================= VISUAL =================
    vis = img.copy()

    for r in results:
        x1, y1, x2, y2 = r["bbox"]

        color = (0, 255, 0) if "MATCH" in r["Verification"] else (0, 0, 255)

        cv2.rectangle(vis, (x1, y1), (x2, y2), color, 2)
        cv2.putText(
            vis,
            f"T:{r['Terminal']}",
            (x1, y1 - 10),
            cv2.FONT_HERSHEY_SIMPLEX,
            0.6,
            color,
            2
        )

    return vis, pd.DataFrame(results).drop(columns=["bbox"], errors="ignore")

# ================= UI =================
with gr.Blocks(title="Terminal Assembly Inspector") as demo:
    gr.Markdown("## Terminal Detector ")
    with gr.Row():
        img_in = gr.Image(type="numpy", label="Input Rail")
        img_out = gr.Image(label="Detections (Red = Error)")
    btn = gr.Button("Analyze Entire Rail", variant="primary")
    table = gr.Dataframe(headers=["Terminal", "Wire", "Verification"])
    btn.click(run_pipeline, [img_in], [img_out, table])

demo.launch()