Send OpenAI fallback images as data URLs

src/main/kotlin/com/android/trisolarisserver/component/DocumentExtractionService.kt

@@ -293,12 +293,17 @@ class DocumentExtractionService(
         }
 
         logger.info("Aadhaar retry failed; using OpenAI fallback")
-        val fallback = openAIVisionClient.extractAadhaarNumber(publicImageUrl) ?: ""
+        val fallback = openAIVisionClient.extractAadhaarNumber(
+            publicImageUrl,
+            document.storagePath,
+            document.contentType
+        ) ?: ""
         val fallbackNormalized = normalizeDigits(cleanedValue(fallback))
         if (fallbackNormalized != null && isValidAadhaar(fallbackNormalized)) {
             results[key] = formatAadhaar(fallbackNormalized)
         } else {
-            logger.warn("OpenAI fallback failed to produce valid Aadhaar")
+            val len = fallbackNormalized?.length ?: 0
+            logger.warn("OpenAI fallback failed to produce valid Aadhaar (digits={})", len)
             results[key] = "NONE"
         }
     }

src/main/kotlin/com/android/trisolarisserver/component/OpenAIVisionClient.kt

@@ -23,7 +23,7 @@ class OpenAIVisionClient(
 ) {
     private val logger = LoggerFactory.getLogger(OpenAIVisionClient::class.java)
 
-    fun extractAadhaarNumber(imageUrl: String): String? {
+    fun extractAadhaarNumber(imageUrl: String, localPath: String?, contentType: String?): String? {
         if (apiKey.isBlank()) {
             logger.warn("OpenAI fallback skipped: openai.apiKey is blank")
             return null
@@ -32,8 +32,9 @@ class OpenAIVisionClient(
         val headers = HttpHeaders()
         headers.contentType = MediaType.APPLICATION_JSON
         headers.setBearerAuth(apiKey)
+        val resolvedImage = buildDataUrl(localPath, contentType) ?: imageUrl
         val first = call(
-            imageUrl,
+            resolvedImage,
             "Read extremely carefully. Aadhaar number = 12 digits. Reply ONLY the 12 digits or NONE.",
             "aadhaar_default",
             headers
@@ -45,7 +46,7 @@ class OpenAIVisionClient(
             logger.info("OpenAI fallback returned NONE; retrying with focused prompt")
         }
         return call(
-            imageUrl,
+            resolvedImage,
             "Focus on the 12-digit Aadhaar number printed on the card (often vertical on the left). Reply ONLY the 12 digits or NONE.",
             "aadhaar_left_strip",
             headers
@@ -130,4 +131,25 @@ class OpenAIVisionClient(
         val digits = trimmed.filter { it.isDigit() }
         return if (digits.isNotBlank()) "digits_len=${digits.length}" else "text_len=${trimmed.length}"
     }
+
+    private fun buildDataUrl(localPath: String?, contentType: String?): String? {
+        if (localPath.isNullOrBlank()) return null
+        val type = contentType ?: guessContentType(localPath) ?: return null
+        return try {
+            val bytes = java.nio.file.Files.readAllBytes(java.nio.file.Paths.get(localPath))
+            val base64 = java.util.Base64.getEncoder().encodeToString(bytes)
+            "data:$type;base64,$base64"
+        } catch (e: Exception) {
+            logger.warn("OpenAI fallback failed to read local image: {}", e.message)
+            null
+        }
+    }
+
+    private fun guessContentType(path: String): String? {
+        return when {
+            path.endsWith(".jpg", true) || path.endsWith(".jpeg", true) -> "image/jpeg"
+            path.endsWith(".png", true) -> "image/png"
+            else -> null
+        }
+    }
 }