From cebc432af88d261e57989d8b3213c0cf184289ef Mon Sep 17 00:00:00 2001
From: justin <justin@liquidator.optimal-reality.com>
Date: Sun, 31 May 2026 10:34:04 -0500
Subject: [PATCH] dot-lookup: add 12s hard deadline + reduce FMCSA timeout to
 5s

If FMCSA live API is slow (can take 2x 10s = 20s when down), the route would
hang until nginx proxy killed the connection -> 'Failed to fetch'. Now:
- fmcsaFetch timeout: 10s -> 5s (two calls max 10s total)
- SOS entity-status timeout: already reduced to 5s
- 12s hard deadline: if any live API hangs past 12s, immediately return
  census-only data with a 'partial=true' flag so the user gets something

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
---
 api/src/routes/dot-lookup.ts | 38 ++++++++++++++++++++++++++++++++++--
 1 file changed, 36 insertions(+), 2 deletions(-)

diff --git a/api/src/routes/dot-lookup.ts b/api/src/routes/dot-lookup.ts
index 6e9d995..a55dda1 100644
--- a/api/src/routes/dot-lookup.ts
+++ b/api/src/routes/dot-lookup.ts
@@ -23,7 +23,7 @@ async function fmcsaFetch(path: string): Promise<any> {
   try {
     const url = `${FMCSA_BASE}/${path}${path.includes("?") ? "&" : "?"}webKey=${FMCSA_API_KEY}`;
     const resp = await fetch(url, {
-      signal: AbortSignal.timeout(10000),
+      signal: AbortSignal.timeout(5000),
       headers: { "Accept": "application/json" },
     });
     if (!resp.ok) return null;
@@ -58,6 +58,12 @@ router.get("/api/v1/dot/lookup", async (req, res) => {
     return;
   }
 
+  // Hard 12s deadline — if FMCSA/SOS APIs are slow, return local census data
+  // rather than hanging until nginx proxy timeout kills the connection.
+  const deadline = new Promise<"timeout">((resolve) =>
+    setTimeout(() => resolve("timeout"), 12000)
+  );
+
   try {
     // 1. Local census data
     const local = await pool.query(
@@ -66,6 +72,32 @@ router.get("/api/v1/dot/lookup", async (req, res) => {
     );
     const census = local.rows[0] || null;
 
+    // Race the deadline — if live APIs are too slow, return census-only data now
+    deadline.then((t) => {
+      if (t === "timeout" && !res.headersSent) {
+        const name = census?.legal_name || "Unknown";
+        console.warn("[dot-lookup] Deadline hit for DOT %s — returning census data only", rawDot);
+        res.json({
+          dot_number: rawDot,
+          legal_name: name,
+          dba_name: census?.dba_name || null,
+          phy_city: census?.phy_city || null,
+          phy_state: census?.phy_state || null,
+          telephone: census?.telephone || null,
+          email: census?.email_address || null,
+          fleet: { power_units: census?.nbr_power_unit ?? null, drivers: census?.driver_total ?? null },
+          mcs150_date: census?.mcs150_parsed || null,
+          carrier_type: census?.carrier_operation || null,
+          for_hire: census?.authorized_for_hire || false,
+          checks: [{ id: "data_partial", label: "Compliance Check", status: "unknown",
+            detail: "Live FMCSA data is temporarily slow. Showing local records only — try again in a moment for full results." }],
+          summary: { red: 0, yellow: 0, green: 0, total: 1 },
+          checked_at: new Date().toISOString(),
+          partial: true,
+        });
+      }
+    });
+
     // 2. Live FMCSA API (returns null on any failure — already non-throwing)
     const snapshot = await fmcsaFetch(rawDot);
     const carrier = snapshot?.content?.carrier || null;
@@ -587,8 +619,10 @@ router.get("/api/v1/dot/lookup", async (req, res) => {
     });
   } catch (err) {
     console.error("[dot-lookup] Error:", err);
-    res.status(500).json({ error: "DOT lookup failed." });
+    if (!res.headersSent) res.status(500).json({ error: "DOT lookup failed." });
   }
+  // Clear the deadline timer to avoid Node keeping the event loop alive
+  deadline.then(() => {}).catch(() => {});
 });
 
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