feat: add OSRM road-snapping for GPS routes and mileage (#21)

Routes now follow actual roads instead of cutting through buildings:
- New OsrmService calls free OSRM Match API to snap GPS points to roads
- Position history endpoint accepts ?matched=true for road-snapped geometry
- Stats use OSRM road distance instead of Haversine crow-flies distance
- Frontend shows solid blue polylines for matched routes, dashed for raw
- Handles chunking (100 coord limit), rate limiting, graceful fallback
- Distance badge shows accurate road miles on route trails

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

backend/src/gps/gps.controller.ts

@@ -132,6 +132,7 @@ export class GpsController {
 
   /**
    * Get a driver's location history (for route trail display)
+   * Query param 'matched=true' returns OSRM road-snapped route
    */
   @Get('locations/:driverId/history')
   @Roles(Role.ADMINISTRATOR)
@@ -139,9 +140,17 @@ export class GpsController {
     @Param('driverId') driverId: string,
     @Query('from') fromStr?: string,
     @Query('to') toStr?: string,
+    @Query('matched') matched?: string,
   ) {
     const from = fromStr ? new Date(fromStr) : undefined;
     const to = toStr ? new Date(toStr) : undefined;
+
+    // If matched=true, return OSRM road-matched route
+    if (matched === 'true') {
+      return this.gpsService.getMatchedRoute(driverId, from, to);
+    }
+
+    // Otherwise return raw GPS points
     return this.gpsService.getDriverLocationHistory(driverId, from, to);
   }
 

backend/src/gps/gps.module.ts

@@ -3,6 +3,7 @@ import { ScheduleModule } from '@nestjs/schedule';
 import { GpsController } from './gps.controller';
 import { GpsService } from './gps.service';
 import { TraccarClientService } from './traccar-client.service';
+import { OsrmService } from './osrm.service';
 import { PrismaModule } from '../prisma/prisma.module';
 import { SignalModule } from '../signal/signal.module';
 
@@ -13,7 +14,7 @@ import { SignalModule } from '../signal/signal.module';
     ScheduleModule.forRoot(),
   ],
   controllers: [GpsController],
-  providers: [GpsService, TraccarClientService],
+  providers: [GpsService, TraccarClientService, OsrmService],
   exports: [GpsService, TraccarClientService],
 })
 export class GpsModule {}

backend/src/gps/gps.service.ts

@@ -10,6 +10,7 @@ import { Cron, CronExpression } from '@nestjs/schedule';
 import { PrismaService } from '../prisma/prisma.service';
 import { SignalService } from '../signal/signal.service';
 import { TraccarClientService } from './traccar-client.service';
+import { OsrmService } from './osrm.service';
 import {
   DriverLocationDto,
   DriverStatsDto,
@@ -29,6 +30,7 @@ export class GpsService implements OnModuleInit {
     private traccarClient: TraccarClientService,
     private signalService: SignalService,
     private configService: ConfigService,
+    private osrmService: OsrmService,
   ) {}
 
   async onModuleInit() {
@@ -514,6 +516,97 @@ Note: GPS tracking is only active during shift hours (${settings.shiftStartHour}
     }));
   }
 
+  /**
+   * Get road-matched route for a driver (snaps GPS points to actual roads)
+   * Returns OSRM-matched coordinates and accurate road distance
+   */
+  async getMatchedRoute(
+    driverId: string,
+    fromDate?: Date,
+    toDate?: Date,
+  ): Promise<{
+    rawPoints: LocationDataDto[];
+    matchedRoute: {
+      coordinates: Array<[number, number]>; // [lat, lng] for Leaflet
+      distance: number; // miles
+      duration: number; // seconds
+      confidence: number; // 0-1
+    } | null;
+  }> {
+    const device = await this.prisma.gpsDevice.findUnique({
+      where: { driverId },
+    });
+
+    if (!device) {
+      throw new NotFoundException('Driver is not enrolled for GPS tracking');
+    }
+
+    // Default to last 4 hours if no date range specified
+    const to = toDate || new Date();
+    const from = fromDate || new Date(to.getTime() - 4 * 60 * 60 * 1000);
+
+    const locations = await this.prisma.gpsLocationHistory.findMany({
+      where: {
+        deviceId: device.id,
+        timestamp: {
+          gte: from,
+          lte: to,
+        },
+      },
+      orderBy: { timestamp: 'asc' },
+    });
+
+    const rawPoints = locations.map((loc) => ({
+      latitude: loc.latitude,
+      longitude: loc.longitude,
+      altitude: loc.altitude,
+      speed: loc.speed,
+      course: loc.course,
+      accuracy: loc.accuracy,
+      battery: loc.battery,
+      timestamp: loc.timestamp,
+    }));
+
+    if (locations.length < 2) {
+      return { rawPoints, matchedRoute: null };
+    }
+
+    // Call OSRM to match route
+    this.logger.log(
+      `[OSRM] Matching route for driver ${driverId}: ${locations.length} points`,
+    );
+
+    const matchResult = await this.osrmService.matchRoute(
+      locations.map((loc) => ({
+        latitude: loc.latitude,
+        longitude: loc.longitude,
+        timestamp: loc.timestamp,
+      })),
+    );
+
+    if (!matchResult) {
+      this.logger.warn('[OSRM] Route matching failed, returning raw points only');
+      return { rawPoints, matchedRoute: null };
+    }
+
+    // Convert distance from meters to miles
+    const distanceMiles = matchResult.distance / 1609.34;
+
+    this.logger.log(
+      `[OSRM] Route matched: ${distanceMiles.toFixed(2)} miles, confidence ${(matchResult.confidence * 100).toFixed(1)}%`,
+    );
+
+    return {
+      rawPoints,
+      matchedRoute: {
+        coordinates: matchResult.coordinates,
+        distance: distanceMiles,
+        duration: matchResult.duration,
+        confidence: matchResult.confidence,
+      },
+    };
+  }
+
   /**
    * Calculate distance between two GPS coordinates using Haversine formula
    * Returns distance in miles
@@ -633,7 +726,7 @@ Note: GPS tracking is only active during shift hours (${settings.shiftStartHour}
 
   /**
    * Get driver's own stats (for driver self-view)
-   * UPDATED: Now calculates distance from GpsLocationHistory table instead of Traccar API
+   * UPDATED: Uses OSRM road-matched distance when available, falls back to Haversine
    */
   async getDriverStats(
     driverId: string,
@@ -664,8 +757,30 @@ Note: GPS tracking is only active during shift hours (${settings.shiftStartHour}
       `[Stats] Calculating stats for driver ${device.driver.name} from ${from.toISOString()} to ${to.toISOString()}`,
     );
 
-    // Calculate total distance from stored position history
+    // Try to get OSRM-matched distance first, fall back to Haversine
-    const totalMiles = await this.calculateDistanceFromHistory(device.id, from, to);
+    let totalMiles = 0;
+    let distanceMethod = 'haversine';
+
+    try {
+      const matchedRoute = await this.getMatchedRoute(driverId, from, to);
+      if (matchedRoute.matchedRoute && matchedRoute.matchedRoute.confidence > 0.5) {
+        totalMiles = matchedRoute.matchedRoute.distance;
+        distanceMethod = 'osrm';
+        this.logger.log(
+          `[Stats] Using OSRM road distance: ${totalMiles.toFixed(2)} miles (confidence ${(matchedRoute.matchedRoute.confidence * 100).toFixed(1)}%)`,
+        );
+      } else {
+        throw new Error('OSRM confidence too low or matching failed');
+      }
+    } catch (error) {
+      this.logger.warn(
+        `[Stats] OSRM matching failed, falling back to Haversine: ${error.message}`,
+      );
+      totalMiles = await this.calculateDistanceFromHistory(device.id, from, to);
+      this.logger.log(
+        `[Stats] Using Haversine distance: ${totalMiles.toFixed(2)} miles`,
+      );
+    }
 
     // Get all positions for speed/time analysis
     const allPositions = await this.prisma.gpsLocationHistory.findMany({
@@ -738,7 +853,7 @@ Note: GPS tracking is only active during shift hours (${settings.shiftStartHour}
         : 0;
 
     this.logger.log(
-      `[Stats] Results: ${totalMiles.toFixed(1)} miles, ${topSpeedMph.toFixed(0)} mph top speed, ${totalTrips} trips, ${totalDrivingMinutes.toFixed(0)} min driving`,
+      `[Stats] Results (${distanceMethod}): ${totalMiles.toFixed(1)} miles, ${topSpeedMph.toFixed(0)} mph top speed, ${totalTrips} trips, ${totalDrivingMinutes.toFixed(0)} min driving`,
     );
 
     return {
@@ -755,6 +870,7 @@ Note: GPS tracking is only active during shift hours (${settings.shiftStartHour}
         averageSpeedMph: Math.round(averageSpeedMph * 10) / 10,
         totalTrips,
         totalDrivingMinutes: Math.round(totalDrivingMinutes),
+        distanceMethod, // 'osrm' or 'haversine'
       },
       recentLocations: recentLocations.map((loc) => ({
         latitude: loc.latitude,

backend/src/gps/osrm.service.ts

@@ -0,0 +1,157 @@
+import { Injectable, Logger } from '@nestjs/common';
+import axios from 'axios';
+
+interface MatchedRoute {
+  coordinates: Array<[number, number]>; // [lat, lng] pairs for Leaflet
+  distance: number; // meters
+  duration: number; // seconds
+  confidence: number;
+}
+
+@Injectable()
+export class OsrmService {
+  private readonly logger = new Logger(OsrmService.name);
+  private readonly baseUrl = 'https://router.project-osrm.org';
+
+  /**
+   * Match GPS coordinates to actual road network.
+   * Splits into chunks of 100 (OSRM limit), returns snapped geometry + road distance.
+   * Coordinates input: array of {latitude, longitude, timestamp}
+   */
+  async matchRoute(
+    points: Array<{ latitude: number; longitude: number; timestamp?: Date }>,
+  ): Promise<MatchedRoute | null> {
+    if (points.length < 2) {
+      this.logger.debug('Not enough points for route matching (minimum 2 required)');
+      return null;
+    }
+
+    try {
+      // Split into chunks of 100 (OSRM limit)
+      const chunks = this.chunkArray(points, 100);
+      let allCoordinates: Array<[number, number]> = [];
+      let totalDistance = 0;
+      let totalDuration = 0;
+      let totalConfidence = 0;
+      let matchCount = 0;
+
+      this.logger.log(
+        `Matching route with ${points.length} points (${chunks.length} chunks)`,
+      );
+
+      for (let i = 0; i < chunks.length; i++) {
+        const chunk = chunks[i];
+
+        // OSRM uses lon,lat format (opposite of Leaflet's lat,lng)
+        const coordString = chunk
+          .map((p) => `${p.longitude},${p.latitude}`)
+          .join(';');
+
+        // Build radiuses (GPS accuracy ~10-25m, allow some flex)
+        const radiuses = chunk.map(() => 25).join(';');
+
+        // Build timestamps if available
+        const timestamps = chunk[0].timestamp
+          ? chunk
+              .map((p) => Math.floor((p.timestamp?.getTime() || 0) / 1000))
+              .join(';')
+          : undefined;
+
+        const params: Record<string, string> = {
+          overview: 'full',
+          geometries: 'geojson',
+          radiuses,
+        };
+        if (timestamps) params.timestamps = timestamps;
+
+        const url = `${this.baseUrl}/match/v1/driving/${coordString}`;
+
+        try {
+          const response = await axios.get(url, { params, timeout: 10000 });
+
+          if (response.data.code === 'Ok' && response.data.matchings?.length > 0) {
+            for (const matching of response.data.matchings) {
+              // GeoJSON coordinates are [lon, lat] - convert to [lat, lng] for Leaflet
+              const coords = matching.geometry.coordinates.map(
+                (c: [number, number]) => [c[1], c[0]] as [number, number],
+              );
+              allCoordinates.push(...coords);
+              totalDistance += matching.distance || 0;
+              totalDuration += matching.duration || 0;
+              totalConfidence += matching.confidence || 0;
+              matchCount++;
+            }
+
+            this.logger.debug(
+              `Chunk ${i + 1}/${chunks.length}: Matched ${response.data.matchings.length} segments`,
+            );
+          } else {
+            this.logger.warn(
+              `OSRM match failed for chunk ${i + 1}: ${response.data.code} - ${response.data.message || 'Unknown error'}`,
+            );
+          }
+        } catch (error) {
+          this.logger.error(
+            `OSRM API error for chunk ${i + 1}: ${error.message}`,
+          );
+          // Continue with next chunk even if this one fails
+        }
+
+        // Rate limit: ~1 req/sec for public OSRM (be conservative)
+        if (chunks.length > 1 && i < chunks.length - 1) {
+          this.logger.debug('Rate limiting: waiting 1.1 seconds before next request');
+          await new Promise((resolve) => setTimeout(resolve, 1100));
+        }
+      }
+
+      if (allCoordinates.length === 0) {
+        this.logger.warn('No coordinates matched from any chunks');
+        return null;
+      }
+
+      const avgConfidence = matchCount > 0 ? totalConfidence / matchCount : 0;
+
+      this.logger.log(
+        `Route matching complete: ${allCoordinates.length} coordinates, ` +
+          `${(totalDistance / 1000).toFixed(2)} km, ` +
+          `confidence ${(avgConfidence * 100).toFixed(1)}%`,
+      );
+
+      return {
+        coordinates: allCoordinates,
+        distance: totalDistance,
+        duration: totalDuration,
+        confidence: avgConfidence,
+      };
+    } catch (error) {
+      this.logger.error(`OSRM match failed: ${error.message}`);
+      return null;
+    }
+  }
+
+  /**
+   * Split array into overlapping chunks for better continuity.
+   * Each chunk overlaps by 5 points with the next chunk.
+   */
+  private chunkArray<T>(array: T[], size: number): T[][] {
+    if (array.length <= size) {
+      return [array];
+    }
+
+    const chunks: T[][] = [];
+    const overlap = 5;
+
+    // Use overlapping chunks (last 5 points overlap with next chunk for continuity)
+    for (let i = 0; i < array.length; i += size - overlap) {
+      const chunk = array.slice(i, Math.min(i + size, array.length));
+      chunks.push(chunk);
+
+      // Stop if we've reached the end
+      if (i + size >= array.length) {
+        break;
+      }
+    }
+
+    return chunks;
+  }
+}

frontend/src/hooks/useGps.ts

@@ -9,6 +9,7 @@ import type {
   EnrollmentResponse,
   MyGpsStatus,
   DeviceQrInfo,
+  LocationHistoryResponse,
 } from '@/types/gps';
 import toast from 'react-hot-toast';
 import { queryKeys } from '@/lib/query-keys';
@@ -125,19 +126,22 @@ export function useDriverLocation(driverId: string) {
 
 /**
  * Get driver location history (for route trail display)
+ * By default, requests road-snapped routes from OSRM map matching
  */
 export function useDriverLocationHistory(driverId: string | null, from?: string, to?: string) {
-  return useQuery<Array<{ latitude: number; longitude: number; speed: number; timestamp: Date }>>({
+  return useQuery({
     queryKey: ['gps', 'locations', driverId, 'history', from, to],
     queryFn: async () => {
       const params = new URLSearchParams();
       if (from) params.append('from', from);
       if (to) params.append('to', to);
+      params.append('matched', 'true'); // Request road-snapped route
       const { data } = await api.get(`/gps/locations/${driverId}/history?${params}`);
       return data;
     },
     enabled: !!driverId,
-    refetchInterval: 30000, // Refresh every 30 seconds
+    refetchInterval: 60000, // Match routes less frequently (60s) since OSRM has rate limits
+    staleTime: 30000, // Consider data fresh for 30s
   });
 }
 

frontend/src/pages/GpsTracking.tsx

@@ -48,7 +48,7 @@ import { useQuery } from '@tanstack/react-query';
 import { api } from '@/lib/api';
 import { useAuth } from '@/contexts/AuthContext';
 import type { Driver } from '@/types';
-import type { DriverLocation } from '@/types/gps';
+import type { DriverLocation, LocationHistoryResponse } from '@/types/gps';
 import toast from 'react-hot-toast';
 import { formatDistanceToNow } from 'date-fns';
 
@@ -151,6 +151,37 @@ export function GpsTracking() {
   const driverIdForTrail = selectedDriverForTrail || (showTrails ? activeDriverIds[0] : null);
   const { data: locationHistory } = useDriverLocationHistory(driverIdForTrail, undefined, undefined);
 
+  // Extract route polyline coordinates and metadata
+  const routePolyline = useMemo(() => {
+    if (!locationHistory) return null;
+
+    const history = locationHistory as LocationHistoryResponse;
+
+    // If we have matched coordinates, use those
+    if (history.matched && history.coordinates && history.coordinates.length > 1) {
+      return {
+        positions: history.coordinates,
+        isMatched: true,
+        distance: history.distance,
+        duration: history.duration,
+        confidence: history.confidence,
+      };
+    }
+
+    // Fall back to raw positions
+    if (history.rawPositions && history.rawPositions.length > 1) {
+      return {
+        positions: history.rawPositions.map(loc => [loc.latitude, loc.longitude] as [number, number]),
+        isMatched: false,
+        distance: undefined,
+        duration: undefined,
+        confidence: undefined,
+      };
+    }
+
+    return null;
+  }, [locationHistory]);
+
   // Mutations
   const updateSettings = useUpdateGpsSettings();
   const traccarSetup = useTraccarSetup();
@@ -383,13 +414,14 @@ export function GpsTracking() {
                   {locations && <MapFitBounds locations={locations} />}
 
                   {/* Route trail polyline */}
-                  {showTrails && locationHistory && locationHistory.length > 1 && (
+                  {showTrails && routePolyline && (
                     <Polyline
-                      positions={locationHistory.map(loc => [loc.latitude, loc.longitude])}
+                      positions={routePolyline.positions}
                       pathOptions={{
-                        color: '#3b82f6',
+                        color: routePolyline.isMatched ? '#3B82F6' : '#94a3b8',
-                        weight: 3,
+                        weight: routePolyline.isMatched ? 4 : 2,
-                        opacity: 0.6,
+                        opacity: routePolyline.isMatched ? 0.7 : 0.4,
+                        dashArray: routePolyline.isMatched ? undefined : '5, 10',
                       }}
                     />
                   )}
@@ -438,7 +470,7 @@ export function GpsTracking() {
               )}
 
               {/* Map Legend & Controls */}
-              <div className="absolute bottom-4 left-4 bg-card/90 backdrop-blur-sm border border-border rounded-lg p-3 z-[1000]">
+              <div className="absolute bottom-4 left-4 bg-card/90 backdrop-blur-sm border border-border rounded-lg p-3 z-[1000] max-w-[220px]">
                 <h4 className="text-sm font-medium text-foreground mb-2">Map Controls</h4>
                 <div className="space-y-2">
                   <div className="flex items-center gap-2">
@@ -450,9 +482,25 @@ export function GpsTracking() {
                     <span className="text-xs text-muted-foreground">Inactive</span>
                   </div>
                   <div className="flex items-center gap-2">
-                    <div className="w-12 h-0.5 bg-blue-500 opacity-60"></div>
+                    <div className="w-12 h-1 bg-blue-500 opacity-70 rounded"></div>
-                    <span className="text-xs text-muted-foreground">Route Trail</span>
+                    <span className="text-xs text-muted-foreground">Road Route</span>
                   </div>
+                  <div className="flex items-center gap-2">
+                    <div className="w-12 h-0.5 bg-gray-400 opacity-40" style={{ borderTop: '2px dashed #94a3b8' }}></div>
+                    <span className="text-xs text-muted-foreground">GPS Trail</span>
+                  </div>
+                  {routePolyline && routePolyline.distance && (
+                    <div className="pt-1 border-t border-border">
+                      <div className="text-xs text-muted-foreground">
+                        Distance: <span className="font-medium text-foreground">{(routePolyline.distance / 1609.34).toFixed(1)} mi</span>
+                      </div>
+                      {routePolyline.confidence !== undefined && (
+                        <div className="text-xs text-muted-foreground">
+                          Confidence: <span className="font-medium text-foreground">{(routePolyline.confidence * 100).toFixed(0)}%</span>
+                        </div>
+                      )}
+                    </div>
+                  )}
                   <hr className="border-border" />
                   <label className="flex items-center gap-2 cursor-pointer">
                     <input