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app.py

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+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()

terminal.json

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+{
+  "panel_name": "IT Lighting Distribution Board No.1",
+  "panel_id": "L2",
+  "drawing_number": "W2503121/2501841",
+  "terminal_blocks": [
+    {"terminal": 0, "signal": "COM", "wire": "COM1", "device": "Common"},
+    {"terminal": 1, "signal": "A01", "wire": "55101", "device": "TR-1 PF Fuse Alarm"},
+    {"terminal": 2, "signal": "A02", "wire": "55102", "device": "TR-1 Temperature Alarm"},
+    {"terminal": 3, "signal": "A03", "wire": "55103", "device": "TR-1 Low Voltage Overload"},
+    {"terminal": 4, "signal": "A04", "wire": "55104", "device": "Panel L1 Breaker Trip"},
+    {"terminal": 5, "signal": "A05", "wire": "55105", "device": "TR-1 Leakage"},
+    {"terminal": 6, "signal": "A06", "wire": "55106", "device": "TR-1 Leakage Ior"},
+    {"terminal": 7, "signal": "A07", "wire": "55107", "device": "TR-2 PF Fuse Alarm"},
+    {"terminal": 8, "signal": "A08", "wire": "55108", "device": "TR-2 Temperature Alarm"},
+    {"terminal": 9, "signal": "A09", "wire": "55109", "device": "TR-2 Low Voltage Overload"},
+    {"terminal": 10, "signal": "A10", "wire": "55110", "device": "Panel L2 Breaker Trip"},
+    {"terminal": 11, "signal": "A11", "wire": "55111", "device": "Panel L2 Breaker Leakage"},
+    {"terminal": 12, "signal": "A12", "wire": "55112", "device": "TR-2 Leakage Ior"},
+    {"terminal": 13, "signal": "A13", "wire": "55113", "device": "TR-3 PF Fuse Alarm"},
+    {"terminal": 14, "signal": "A14", "wire": "55114", "device": "TR-3 Temperature Alarm"},
+    {"terminal": 15, "signal": "A15", "wire": "55115", "device": "TR-3 Low Voltage Overload"},
+    {"terminal": 16, "signal": "A16", "wire": "55116", "device": "Panel L3 Breaker Trip"},
+    {"terminal": 17, "signal": "A17", "wire": "55117", "device": "Panel L3 Breaker Leakage"},
+    {"terminal": 18, "signal": "A18", "wire": "55118", "device": "TR-3 Leakage"},
+    {"terminal": 19, "signal": "A19", "wire": "55119", "device": "TR-3 Leakage Ior"},
+    {"terminal": 20, "signal": "A20", "wire": "55120", "device": "Common"},
+
+    {"terminal": 21, "signal": "T1CA", "wire": "T1CA", "device": "TR-1 Energy Meter Pulse +"},
+    {"terminal": 22, "signal": "T1CB", "wire": "T1CB", "device": "TR-1 Energy Meter Pulse -"},
+    {"terminal": 23, "signal": "T2CA", "wire": "T2CA", "device": "TR-2 Energy Meter Pulse +"},
+    {"terminal": 24, "signal": "T2CB", "wire": "T2CB", "device": "TR-2 Energy Meter Pulse -"},
+    {"terminal": 25, "signal": "T3CA", "wire": "T3CA", "device": "TR-3 Energy Meter Pulse +"},
+    {"terminal": 26, "signal": "T3CB", "wire": "T3CB", "device": "TR-3 Energy Meter Pulse -"},
+
+    {"terminal": 27, "signal": "IL11CA", "wire": "IL11CA", "device": "Energy Meter 22IL1-1"},
+    {"terminal": 28, "signal": "IL11CB", "wire": "IL11CB", "device": "Energy Meter 22IL1-1"},
+    {"terminal": 29, "signal": "IL12CA", "wire": "IL12CA", "device": "Energy Meter 22IL1-2"},
+    {"terminal": 30, "signal": "IL12CB", "wire": "IL12CB", "device": "Energy Meter 22IL1-2"},
+    {"terminal": 31, "signal": "IL13CA", "wire": "IL13CA", "device": "Energy Meter 22IL1-3"},
+    {"terminal": 32, "signal": "IL13CB", "wire": "IL13CB", "device": "Energy Meter 22IL1-3"},
+    {"terminal": 33, "signal": "IL14CA", "wire": "IL14CA", "device": "Energy Meter 22IL1-4"},
+    {"terminal": 34, "signal": "IL14CB", "wire": "IL14CB", "device": "Energy Meter 22IL1-4"},
+
+    {"terminal": 35, "signal": "IL15CA", "wire": "IL15CA", "device": "Energy Meter 22IL1-5"},
+    {"terminal": 36, "signal": "IL15CB", "wire": "IL15CB", "device": "Energy Meter 22IL1-5"},
+    {"terminal": 37, "signal": "IL16CA", "wire": "IL16CA", "device": "Energy Meter 22IL1-6"},
+    {"terminal": 38, "signal": "IL16CB", "wire": "IL16CB", "device": "Energy Meter 22IL1-6"},
+    {"terminal": 39, "signal": "IL17CA", "wire": "IL17CA", "device": "Energy Meter 22IL1-7"},
+    {"terminal": 40, "signal": "IL17CB", "wire": "IL17CB", "device": "Energy Meter 22IL1-7"},
+    {"terminal": 41, "signal": "IL18CA", "wire": "IL18CA", "device": "Energy Meter 22IL1-8"},
+    {"terminal": 42, "signal": "IL18CB", "wire": "IL18CB", "device": "Energy Meter 22IL1-8"},
+    {"terminal": 43, "signal": "IL19CA", "wire": "IL19CA", "device": "Energy Meter 22IL1-9"},
+    {"terminal": 44, "signal": "IL19CB", "wire": "IL19CB", "device": "Energy Meter 22IL1-9"},
+
+    {"terminal": 45, "signal": "IL110CA", "wire": "IL110CA", "device": "Energy Meter 22IL1-10"},
+    {"terminal": 46, "signal": "IL110CB", "wire": "IL110CB", "device": "Energy Meter 22IL1-10"},
+    {"terminal": 47, "signal": "IL111CA", "wire": "IL111CA", "device": "Energy Meter 22IL1-11"},
+    {"terminal": 48, "signal": "IL111CB", "wire": "IL111CB", "device": "Energy Meter 22IL1-11"},
+    {"terminal": 49, "signal": "IL112CA", "wire": "IL112CA", "device": "Energy Meter 22IL1-12"},
+    {"terminal": 50, "signal": "IL112CB", "wire": "IL112CB", "device": "Energy Meter 22IL1-12"},
+    {"terminal": 51, "signal": "IL113CA", "wire": "IL113CA", "device": "Energy Meter 22IL1-13"},
+    {"terminal": 52, "signal": "IL113CB", "wire": "IL113CB", "device": "Energy Meter 22IL1-13"},
+    {"terminal": 53, "signal": "IL114CA", "wire": "IL114CA", "device": "Energy Meter 22IL1-14"},
+    {"terminal": 54, "signal": "IL114CB", "wire": "IL114CB", "device": "Energy Meter 22IL1-14"},
+
+    {"terminal": 55, "signal": "IL115CA", "wire": "IL115CA", "device": "Energy Meter 22IL1-15"},
+    {"terminal": 56, "signal": "IL115CB", "wire": "IL115CB", "device": "Energy Meter 22IL1-15"},
+    {"terminal": 57, "signal": "IL116CA", "wire": "IL116CA", "device": "Energy Meter 22IL1-16"},
+    {"terminal": 58, "signal": "IL116CB", "wire": "IL116CB", "device": "Energy Meter 22IL1-16"},
+    {"terminal": 59, "signal": "IL117CA", "wire": "IL117CA", "device": "Energy Meter 22IL1-17"},
+    {"terminal": 60, "signal": "IL117CB", "wire": "IL117CB", "device": "Energy Meter 22IL1-17"},
+    {"terminal": 61, "signal": "IL118CA", "wire": "IL118CA", "device": "Energy Meter 22IL1-18"},
+    {"terminal": 62, "signal": "IL118CB", "wire": "IL118CB", "device": "Energy Meter 22IL1-18"},
+    {"terminal": 63, "signal": "IL119CA", "wire": "IL119CA", "device": "Energy Meter 22IL1-19"},
+    {"terminal": 64, "signal": "IL119CB", "wire": "IL119CB", "device": "Energy Meter 22IL1-19"},
+
+    {"terminal": 65, "signal": "IL120CA", "wire": "IL120CA", "device": "Energy Meter 22IL1-20"},
+    {"terminal": 66, "signal": "IL120CB", "wire": "IL120CB", "device": "Energy Meter 22IL1-20"},
+    {"terminal": 67, "signal": "IL121CA", "wire": "IL121CA", "device": "Energy Meter 22IL1-21"},
+    {"terminal": 68, "signal": "IL121CB", "wire": "IL121CB", "device": "Energy Meter 22IL1-21"},
+    {"terminal": 69, "signal": "IL122CA", "wire": "IL122CA", "device": "Energy Meter 22IL1-22"},
+    {"terminal": 70, "signal": "IL122CB", "wire": "IL122CB", "device": "Energy Meter 22IL1-22"},
+    {"terminal": 71, "signal": "IL123CA", "wire": "IL123CA", "device": "Energy Meter 22IL1-23"},
+    {"terminal": 72, "signal": "IL123CB", "wire": "IL123CB", "device": "Energy Meter 22IL1-23"},
+    {"terminal": 73, "signal": "IL124CA", "wire": "IL124CA", "device": "Energy Meter 22IL1-24"},
+    {"terminal": 74, "signal": "IL124CB", "wire": "IL124CB", "device": "Energy Meter 22IL1-24"},
+
+    {"terminal": 75, "signal": "IL21CA", "wire": "IL21CA", "device": "Energy Meter 22IL2-1"},
+    {"terminal": 76, "signal": "IL21CB", "wire": "IL21CB", "device": "Energy Meter 22IL2-1"},
+    {"terminal": 77, "signal": "IL22CA", "wire": "IL22CA", "device": "Energy Meter 22IL2-2"},
+    {"terminal": 78, "signal": "IL22CB", "wire": "IL22CB", "device": "Energy Meter 22IL2-2"},
+    {"terminal": 79, "signal": "IL23CA", "wire": "IL23CA", "device": "Energy Meter 22IL2-3"},
+    {"terminal": 80, "signal": "IL23CB", "wire": "IL23CB", "device": "Energy Meter 22IL2-3"},
+    {"terminal": 81, "signal": "IL24CA", "wire": "IL24CA", "device": "Energy Meter 22IL2-4"},
+    {"terminal": 82, "signal": "IL24CB", "wire": "IL24CB", "device": "Energy Meter 22IL2-4"},
+    {"terminal": 83, "signal": "IL25CA", "wire": "IL25CA", "device": "Energy Meter 22IL2-5"},
+    {"terminal": 84, "signal": "IL25CB", "wire": "IL25CB", "device": "Energy Meter 22IL2-5"},
+    {"terminal": 85, "signal": "IL26CA", "wire": "IL26CA", "device": "Energy Meter 22IL2-6"},
+    {"terminal": 86, "signal": "IL26CB", "wire": "IL26CB", "device": "Energy Meter 22IL2-6"},
+    {"terminal": 87, "signal": "IL27CA", "wire": "IL27CA", "device": "Energy Meter 22IL2-7"},
+    {"terminal": 88, "signal": "IL27CB", "wire": "IL27CB", "device": "Energy Meter 22IL2-7"},
+    {"terminal": 89, "signal": "IL28CA", "wire": "IL28CA", "device": "Energy Meter 22IL2-8"},
+    {"terminal": 90, "signal": "IL28CB", "wire": "IL28CB", "device": "Energy Meter 22IL2-8"},
+    {"terminal": 91, "signal": "IL29CA", "wire": "IL29CA", "device": "Energy Meter 22IL2-9"},
+    {"terminal": 92, "signal": "IL29CB", "wire": "IL29CB", "device": "Energy Meter 22IL2-9"},
+    {"terminal": 93, "signal": "IL210CA", "wire": "IL210CA", "device": "Energy Meter 22IL2-10"},
+    {"terminal": 94, "signal": "IL210CB", "wire": "IL210CB", "device": "Energy Meter 22IL2-10"},
+
+    {"terminal": 95, "signal": "SPARE", "wire": null, "device": "Spare"},
+    {"terminal": 96, "signal": "SPARE", "wire": null, "device": "Spare"},
+    {"terminal": 97, "signal": "SPARE", "wire": null, "device": "Spare"},
+    {"terminal": 98, "signal": "SPARE", "wire": null, "device": "Spare"},
+    {"terminal": 99, "signal": "SPARE", "wire": null, "device": "Spare"}
+
+  ]
+}