fix: OCR API error

backend/src/features/ocr/api/ocr.controller.ts

@@ -123,6 +123,106 @@ export class OcrController {
     }
   }
 
+  /**
+   * POST /api/ocr/extract/vin
+   * Extract VIN from an uploaded image using VIN-specific OCR.
+   */
+  async extractVin(
+    request: FastifyRequest,
+    reply: FastifyReply
+  ) {
+    const userId = (request as any).user?.sub as string;
+
+    logger.info('VIN extract requested', {
+      operation: 'ocr.controller.extractVin',
+      userId,
+    });
+
+    const file = await (request as any).file({ limits: { files: 1 } });
+    if (!file) {
+      logger.warn('No file provided for VIN extraction', {
+        operation: 'ocr.controller.extractVin.no_file',
+        userId,
+      });
+      return reply.code(400).send({
+        error: 'Bad Request',
+        message: 'No file provided',
+      });
+    }
+
+    const contentType = file.mimetype as string;
+    if (!SUPPORTED_TYPES.has(contentType)) {
+      logger.warn('Unsupported file type for VIN extraction', {
+        operation: 'ocr.controller.extractVin.unsupported_type',
+        userId,
+        contentType,
+        fileName: file.filename,
+      });
+      return reply.code(415).send({
+        error: 'Unsupported Media Type',
+        message: `Unsupported file type: ${contentType}. Supported: JPEG, PNG, HEIC, PDF`,
+      });
+    }
+
+    const chunks: Buffer[] = [];
+    for await (const chunk of file.file) {
+      chunks.push(chunk);
+    }
+    const fileBuffer = Buffer.concat(chunks);
+
+    if (fileBuffer.length === 0) {
+      logger.warn('Empty file provided for VIN extraction', {
+        operation: 'ocr.controller.extractVin.empty_file',
+        userId,
+        fileName: file.filename,
+      });
+      return reply.code(400).send({
+        error: 'Bad Request',
+        message: 'Empty file provided',
+      });
+    }
+
+    try {
+      const result = await ocrService.extractVin(userId, {
+        fileBuffer,
+        contentType,
+      });
+
+      logger.info('VIN extract completed', {
+        operation: 'ocr.controller.extractVin.success',
+        userId,
+        success: result.success,
+        processingTimeMs: result.processingTimeMs,
+      });
+
+      return reply.code(200).send(result);
+    } catch (error: any) {
+      if (error.statusCode === 413) {
+        return reply.code(413).send({
+          error: 'Payload Too Large',
+          message: error.message,
+        });
+      }
+      if (error.statusCode === 415) {
+        return reply.code(415).send({
+          error: 'Unsupported Media Type',
+          message: error.message,
+        });
+      }
+
+      logger.error('VIN extract failed', {
+        operation: 'ocr.controller.extractVin.error',
+        userId,
+        error: error.message,
+      });
+
+      return reply.code(500).send({
+        error: 'Internal Server Error',
+        message: 'VIN extraction failed',
+      });
+    }
+  }
+
   /**
    * POST /api/ocr/jobs
    * Submit an async OCR job for large files.

backend/src/features/ocr/api/ocr.routes.ts

@@ -17,6 +17,12 @@ export const ocrRoutes: FastifyPluginAsync = async (
     handler: ctrl.extract.bind(ctrl),
   });
 
+  // POST /api/ocr/extract/vin - VIN-specific OCR extraction
+  fastify.post('/ocr/extract/vin', {
+    preHandler: [requireAuth],
+    handler: ctrl.extractVin.bind(ctrl),
+  });
+
   // POST /api/ocr/jobs - Submit async OCR job
   fastify.post('/ocr/jobs', {
     preHandler: [requireAuth],

backend/src/features/ocr/domain/ocr.service.ts

@@ -8,6 +8,7 @@ import type {
   OcrExtractRequest,
   OcrJobSubmitRequest,
   OcrResponse,
+  VinExtractionResponse,
 } from './ocr.types';
 
 /** Maximum file size for sync processing (10MB) */
@@ -92,6 +93,63 @@ export class OcrService {
     }
   }
 
+  /**
+   * Extract VIN from an image using VIN-specific OCR.
+   *
+   * @param userId - User ID for logging
+   * @param request - OCR extraction request
+   * @returns VIN extraction result
+   */
+  async extractVin(userId: string, request: OcrExtractRequest): Promise<VinExtractionResponse> {
+    if (request.fileBuffer.length > MAX_SYNC_SIZE) {
+      const err: any = new Error(
+        `File too large. Max: ${MAX_SYNC_SIZE / (1024 * 1024)}MB.`
+      );
+      err.statusCode = 413;
+      throw err;
+    }
+
+    if (!SUPPORTED_TYPES.has(request.contentType)) {
+      const err: any = new Error(
+        `Unsupported file type: ${request.contentType}. Supported: ${[...SUPPORTED_TYPES].join(', ')}`
+      );
+      err.statusCode = 415;
+      throw err;
+    }
+
+    logger.info('VIN extract requested', {
+      operation: 'ocr.service.extractVin',
+      userId,
+      contentType: request.contentType,
+      fileSize: request.fileBuffer.length,
+    });
+
+    try {
+      const result = await ocrClient.extractVin(
+        request.fileBuffer,
+        request.contentType
+      );
+
+      logger.info('VIN extract completed', {
+        operation: 'ocr.service.extractVin.success',
+        userId,
+        success: result.success,
+        vin: result.vin,
+        confidence: result.confidence,
+        processingTimeMs: result.processingTimeMs,
+      });
+
+      return result;
+    } catch (error) {
+      logger.error('VIN extract failed', {
+        operation: 'ocr.service.extractVin.error',
+        userId,
+        error: error instanceof Error ? error.message : 'Unknown error',
+      });
+      throw error;
+    }
+  }
+
   /**
    * Submit an async OCR job for large files.
    *

backend/src/features/ocr/domain/ocr.types.ts

@@ -45,6 +45,17 @@ export interface OcrExtractRequest {
   preprocess?: boolean;
 }
 
+/** Response from VIN-specific extraction */
+export interface VinExtractionResponse {
+  success: boolean;
+  vin: string | null;
+  confidence: number;
+  boundingBox: { x: number; y: number; width: number; height: number } | null;
+  alternatives: { vin: string; confidence: number }[];
+  processingTimeMs: number;
+  error: string | null;
+}
+
 /** Internal request to submit async job */
 export interface OcrJobSubmitRequest {
   fileBuffer: Buffer;

backend/src/features/ocr/external/ocr-client.ts

@@ -1,9 +1,8 @@
 /**
  * @ai-summary HTTP client for OCR service communication
  */
-import FormData from 'form-data';
 import { logger } from '../../../core/logging/logger';
-import type { JobResponse, OcrResponse } from '../domain/ocr.types';
+import type { JobResponse, OcrResponse, VinExtractionResponse } from '../domain/ocr.types';
 
 /** OCR service configuration */
 const OCR_SERVICE_URL = process.env.OCR_SERVICE_URL || 'http://mvp-ocr:8000';
@@ -32,12 +31,7 @@ export class OcrClient {
     contentType: string,
     preprocess: boolean = true
   ): Promise<OcrResponse> {
-    const formData = new FormData();
+    const formData = this.buildFormData(fileBuffer, contentType);
-    formData.append('file', fileBuffer, {
-      filename: this.getFilenameFromContentType(contentType),
-      contentType,
-    });
-
     const url = `${this.baseUrl}/extract?preprocess=${preprocess}`;
 
     logger.info('OCR extract request', {
@@ -50,8 +44,7 @@ export class OcrClient {
 
     const response = await this.fetchWithTimeout(url, {
       method: 'POST',
-      body: formData as any,
+      body: formData,
-      headers: formData.getHeaders(),
     });
 
     if (!response.ok) {
@@ -77,6 +70,55 @@ export class OcrClient {
     return result;
   }
 
+  /**
+   * Extract VIN from an image using VIN-specific OCR.
+   *
+   * @param fileBuffer - Image file buffer
+   * @param contentType - MIME type of the file
+   * @returns VIN extraction result
+   */
+  async extractVin(
+    fileBuffer: Buffer,
+    contentType: string
+  ): Promise<VinExtractionResponse> {
+    const formData = this.buildFormData(fileBuffer, contentType);
+    const url = `${this.baseUrl}/extract/vin`;
+
+    logger.info('OCR VIN extract request', {
+      operation: 'ocr.client.extractVin',
+      url,
+      contentType,
+      fileSize: fileBuffer.length,
+    });
+
+    const response = await this.fetchWithTimeout(url, {
+      method: 'POST',
+      body: formData,
+    });
+
+    if (!response.ok) {
+      const errorText = await response.text();
+      logger.error('OCR VIN extract failed', {
+        operation: 'ocr.client.extractVin.error',
+        status: response.status,
+        error: errorText,
+      });
+      throw new Error(`OCR service error: ${response.status} - ${errorText}`);
+    }
+
+    const result = (await response.json()) as VinExtractionResponse;
+
+    logger.info('OCR VIN extract completed', {
+      operation: 'ocr.client.extractVin.success',
+      success: result.success,
+      vin: result.vin,
+      confidence: result.confidence,
+      processingTimeMs: result.processingTimeMs,
+    });
+
+    return result;
+  }
+
   /**
    * Submit an async OCR job for large files.
    *
@@ -90,11 +132,7 @@ export class OcrClient {
     contentType: string,
     callbackUrl?: string
   ): Promise<JobResponse> {
-    const formData = new FormData();
+    const formData = this.buildFormData(fileBuffer, contentType);
-    formData.append('file', fileBuffer, {
-      filename: this.getFilenameFromContentType(contentType),
-      contentType,
-    });
     if (callbackUrl) {
       formData.append('callback_url', callbackUrl);
     }
@@ -111,8 +149,7 @@ export class OcrClient {
 
     const response = await this.fetchWithTimeout(url, {
       method: 'POST',
-      body: formData as any,
+      body: formData,
-      headers: formData.getHeaders(),
     });
 
     if (!response.ok) {
@@ -205,6 +242,14 @@ export class OcrClient {
     }
   }
 
+  private buildFormData(fileBuffer: Buffer, contentType: string): FormData {
+    const filename = this.getFilenameFromContentType(contentType);
+    const blob = new Blob([fileBuffer], { type: contentType });
+    const formData = new FormData();
+    formData.append('file', blob, filename);
+    return formData;
+  }
+
   private getFilenameFromContentType(contentType: string): string {
     const extensions: Record<string, string> = {
       'image/jpeg': 'image.jpg',

frontend/src/features/vehicles/hooks/useVinOcr.ts

@@ -41,13 +41,13 @@ export interface UseVinOcrReturn extends UseVinOcrState {
 }
 
 /**
- * Extract VIN from image using OCR service
+ * Extract VIN from image using VIN-specific OCR endpoint
  */
 async function extractVinFromImage(file: File): Promise<VinOcrResult> {
   const formData = new FormData();
   formData.append('file', file);
 
-  const response = await apiClient.post('/ocr/extract', formData, {
+  const response = await apiClient.post('/ocr/extract/vin', formData, {
     headers: { 'Content-Type': 'multipart/form-data' },
     timeout: 30000, // 30 seconds for OCR processing
   });
@@ -55,19 +55,17 @@ async function extractVinFromImage(file: File): Promise<VinOcrResult> {
   const data = response.data;
 
   if (!data.success) {
-    throw new Error('OCR extraction failed');
+    throw new Error(data.error || 'VIN extraction failed');
   }
 
-  // Extract VIN from the response
+  if (!data.vin) {
-  const vinField = data.extractedFields?.vin;
-  if (!vinField?.value) {
     throw new Error('No VIN found in image. Please ensure the VIN is clearly visible.');
   }
 
   return {
-    vin: vinField.value.toUpperCase().replace(/[^A-HJ-NPR-Z0-9]/g, ''),
+    vin: data.vin.toUpperCase().replace(/[^A-HJ-NPR-Z0-9]/g, ''),
-    confidence: vinField.confidence,
+    confidence: data.confidence,
-    rawText: data.rawText,
+    rawText: data.vin,
   };
 }