fix(routing): make low-level pairs pass IFPS (LFRS-LFST)

Three router bugs surfaced by testing real filed pairs against the
Eurocontrol IFPUV oracle:

- ROUTE130 repair now collapses the leg chain when dropping an unknown
  designator (a computer-nav fix like GT27A on an airway), instead of
  leaving a dangling `AWY AWY`. Same airway on both sides -> merge; else DCT.
- FL detour ratio 1.6 -> 1.25: the FL-filtered graph fragments the
  conventional (<=FL195) network and forced an absurd London detour for a
  domestic French hop; the short full route now wins.
- FL ceiling-cap: file a short low-level pair at its airways' natural
  ceiling instead of an optimistic FL360 (which yields PROF195 on every
  leg). Gated on upper-network fragmentation so genuine high-level
  long-haul (EGLL-LSZH) is never wrongly lowered.
- New PROF195 repair lowers the cruise FL to where the cited airway exists.

LFRS-LFST now no-error at FL080 (0 iterations); LFRN-LFMN and LSGG-LFPO
still pass and now converge in 0 iterations. 4 new unit tests; 49 green.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

crates/core/src/api.rs

@@ -439,6 +439,31 @@ pub fn discover_route(
         None => (Vec::new(), Vec::new()),
     };
 
+    // Cap the start FL to the airway route's natural ceiling *only when the upper
+    // network fragments* for this pair. A short low-level pair (e.g. LFRS–LFST,
+    // direct airways cap at FL195) fragments: its FL-filtered route detours badly
+    // vs. the full route, so we fly low at the full route's ceiling. A normal
+    // high-level pair (e.g. EGLL–LSZH) routes cleanly on the upper network, so we
+    // must NOT lower it just because its shortest full path dips through one
+    // low-cap airway. This is the same detour test as `plan_route_best`.
+    const FRAG_RATIO: f64 = 1.25;
+    let dep_fixes: Vec<String> = dep_sid.iter().map(|(_, f)| f.clone()).collect();
+    let dest_fixes: Vec<String> = dest_star.iter().map(|(_, f)| f.clone()).collect();
+    let full = routing::plan_route_conn(&conn, &from, &to, None, &dep_fixes, &dest_fixes).ok();
+    let fl_route = routing::plan_route_conn(&conn, &from, &to, Some(start_fl), &dep_fixes, &dest_fixes).ok();
+    let fragmented = match (&full, &fl_route) {
+        (Some(full), Some(fl)) => !(fl.via_airways && fl.total_nm <= FRAG_RATIO * full.total_nm.max(1.0)),
+        _ => false,
+    };
+    let start_fl = match full
+        .as_ref()
+        .filter(|_| fragmented)
+        .and_then(|r| routing::route_fl_ceiling(&conn, r).ok().flatten())
+    {
+        Some(ceil) if ceil < start_fl => (ceil / 10) * 10,
+        _ => start_fl,
+    };
+
     let result = routing::discover::find_valid_route(
         &conn, &from, &to, &dep_sid, &dest_star, start_fl, rad, validator,
     )?;

crates/core/src/routing/discover.rs

@@ -115,6 +115,20 @@ fn parse_fl_gap(msg: &str) -> Option<(String, String)> {
     Some((a.to_owned(), b.to_owned()))
 }
 
+/// The valid `(lo, hi)` FL band from a PROF195 message, e.g.
+/// `DIK T856 ADUSU DOES NOT EXIST IN FL RANGE F000..F245` → `(0, 245)`.
+/// The airway exists only inside this band, so a cruise FL above `hi` (or below
+/// `lo`) is the fault.
+fn parse_valid_range(msg: &str) -> Option<(i32, i32)> {
+    let up = msg.to_uppercase();
+    let tail = up.split("FL RANGE ").nth(1)?.trim();
+    let (lo, hi) = tail.split_once("..")?;
+    let num = |s: &str| -> Option<i32> {
+        s.trim().trim_start_matches('F').chars().take_while(|c| c.is_ascii_digit()).collect::<String>().parse().ok()
+    };
+    Some((num(lo)?, num(hi)?))
+}
+
 /// A forbidden flight-level band expressed by a PROF204/205 message.
 #[derive(Default, Clone, Copy)]
 struct Band {
@@ -179,9 +193,36 @@ fn apply_repairs(
     fl: i32,
     errors: &[IfpsErr],
 ) -> Result<Option<(Route, i32, String)>> {
-    // 1) Re-route a broken segment through the FL-filtered airway graph:
+    // 1) PROF195 above an airway's ceiling → the cruise FL is too high for this
-    //    ROUTE165 (DCT too long in a TMA) and PROF195 (airway not valid at this
+    //    route (a short low-level pair whose direct airways cap at, say, FL195,
-    //    FL — e.g. we lowered FL for a RAD cap and broke a high-level airway).
+    //    filed at FL270). Lower to a level where the airways exist and re-plan,
+    //    rather than detour around them. `hi` is the airway's top; we drop to the
+    //    highest 10s FL at/below the lowest violated ceiling.
+    let prof195_ceiling = errors
+        .iter()
+        .filter(|e| e.code == "PROF195")
+        .filter_map(|e| parse_valid_range(&e.msg))
+        .filter(|&(_lo, hi)| fl > hi)
+        .map(|(_lo, hi)| hi)
+        .min();
+    if let Some(ceil) = prof195_ceiling {
+        let target = (ceil / 10) * 10; // valid cruise level at/below the ceiling
+        if target != fl && target >= 60 {
+            let replanned = super::plan_route_best(conn, from, to, Some(target), dep_fixes, dest_fixes)
+                .ok()
+                .filter(|r| r.legs.len() >= 2);
+            let (route, how) = match replanned {
+                Some(r) => (r, "re-planned"),
+                None => (route.clone(), "same route"),
+            };
+            return Ok(Some((route, target, format!("PROF195 ceiling → {} ({how})", fl3(target)))));
+        }
+    }
+
+    // 2) Re-route a broken segment through the FL-filtered airway graph:
+    //    ROUTE165 (DCT too long in a TMA) and PROF195 where lowering didn't apply
+    //    (airway invalid because we're *below* its base — e.g. we over-lowered for
+    //    a RAD cap and broke a high-level airway).
     let mut segs: Vec<(String, String)> = errors
         .iter()
         .filter_map(|e| match e.code.as_str() {
@@ -261,25 +302,23 @@ fn apply_repairs(
         }
     }
 
-    // 3) unknown designators → drop the token.
+    // 3) unknown designators → drop the token (collapsing the leg chain so we
-    let drop: Vec<String> = errors
+    //    never leave a dangling `AWY AWY`).
+    let drop: std::collections::HashSet<String> = errors
         .iter()
         .filter(|e| e.code == "ROUTE130")
         .filter_map(|e| parse_unknown(&e.msg))
         .collect();
     if !drop.is_empty() {
-        let legs: Vec<Leg> = route
+        let legs = drop_designators(&route.legs, &drop);
-            .legs
+        if legs.len() != route.legs.len() && !legs.is_empty() {
-            .iter()
-            .filter(|l| !drop.iter().any(|d| d == &l.to || d == &l.airway))
-            .cloned()
-            .collect();
-        if legs.len() != route.legs.len() && legs.len() >= 1 {
             let nm = total_nm(&legs);
+            let mut names: Vec<&str> = drop.iter().map(String::as_str).collect();
+            names.sort_unstable();
             return Ok(Some((
                 Route { legs, total_nm: nm, via_airways: route.via_airways },
                 fl,
-                format!("drop {}", drop.join(", ")),
+                format!("drop {}", names.join(", ")),
             )));
         }
     }
@@ -287,6 +326,63 @@ fn apply_repairs(
     Ok(None)
 }
 
+/// Remove unknown designators from a leg chain without breaking it.
+///
+/// * An **airway** designator in `drop` → that leg becomes a `DCT` between its
+///   endpoints (keep the waypoints, drop the bad airway).
+/// * A **waypoint** designator in `drop` (a leg's `to`) → merge the leg into the
+///   next one: `A --awy1--> W --awy2--> B` becomes `A --awy--> B` where `awy` is
+///   the shared airway if `awy1 == awy2`, else `DCT`. Consecutive dropped
+///   waypoints are absorbed in one pass. Distances are summed (consecutive
+///   segments), which is exact for the same-airway case and a safe over-estimate
+///   otherwise.
+fn drop_designators(legs: &[Leg], drop: &std::collections::HashSet<String>) -> Vec<Leg> {
+    // Pass 1: bad airways → DCT (endpoints preserved).
+    let staged: Vec<Leg> = legs
+        .iter()
+        .map(|l| {
+            if drop.contains(&l.airway) {
+                Leg { airway: "DCT".to_owned(), ..l.clone() }
+            } else {
+                l.clone()
+            }
+        })
+        .collect();
+
+    // Pass 2: merge out legs whose `to` is a dropped waypoint.
+    let mut out: Vec<Leg> = Vec::with_capacity(staged.len());
+    let mut i = 0;
+    while i < staged.len() {
+        let leg = &staged[i];
+        if drop.contains(&leg.to) && i + 1 < staged.len() {
+            let from = leg.from.clone();
+            let start_awy = leg.airway.clone();
+            let mut acc = leg.dist_nm;
+            let mut j = i + 1;
+            acc += staged[j].dist_nm;
+            let mut same = staged[j].airway == start_awy;
+            let mut end_to = staged[j].to.clone();
+            while drop.contains(&end_to) && j + 1 < staged.len() {
+                j += 1;
+                acc += staged[j].dist_nm;
+                same &= staged[j].airway == start_awy;
+                end_to = staged[j].to.clone();
+            }
+            let airway = if same { start_awy } else { "DCT".to_owned() };
+            out.push(Leg { from, to: end_to, airway, dist_nm: acc });
+            i = j + 1;
+        } else if drop.contains(&leg.to) {
+            // Trailing leg ends at a dropped waypoint (no next leg to merge into):
+            // drop this leg so the route ends at the previous point.
+            i += 1;
+        } else {
+            out.push(leg.clone());
+            i += 1;
+        }
+    }
+    out
+}
+
 // ── the loop ────────────────────────────────────────────────────────────────
 
 /// Maximum validate/repair iterations (each is one live IFPUV round-trip).
@@ -550,6 +646,53 @@ mod tests {
             parse_fl_gap("DIK T856 ADUSU DOES NOT EXIST IN FL RANGE F000..F245"),
             Some(("DIK".into(), "ADUSU".into()))
         );
+        assert_eq!(
+            parse_valid_range("DIK T856 ADUSU DOES NOT EXIST IN FL RANGE F000..F245"),
+            Some((0, 245))
+        );
+        assert_eq!(
+            parse_valid_range("ANG H34 SABLE DOES NOT EXIST IN FL RANGE F055..F195"),
+            Some((55, 195))
+        );
+    }
+
+    #[test]
+    fn drop_designator_collapses_same_airway() {
+        // SUTAL N852 GT27A N852 AKELU  → drop GT27A → SUTAL N852 AKELU (not `N852 N852`).
+        let leg = |f: &str, t: &str, a: &str| Leg {
+            from: f.into(), to: t.into(), airway: a.into(), dist_nm: 10.0,
+        };
+        let legs = vec![
+            leg("SUTAL", "GT27A", "N852"),
+            leg("GT27A", "AKELU", "N852"),
+            leg("AKELU", "GTQ", "N852"),
+        ];
+        let drop = std::collections::HashSet::from(["GT27A".to_owned()]);
+        let out = drop_designators(&legs, &drop);
+        let s: Vec<(String, String, String)> =
+            out.iter().map(|l| (l.from.clone(), l.airway.clone(), l.to.clone())).collect();
+        assert_eq!(
+            s,
+            vec![
+                ("SUTAL".into(), "N852".into(), "AKELU".into()),
+                ("AKELU".into(), "N852".into(), "GTQ".into()),
+            ]
+        );
+        // Distance of the merged leg = sum of the two collapsed segments.
+        assert_eq!(out[0].dist_nm, 20.0);
+    }
+
+    #[test]
+    fn drop_designator_different_airways_becomes_dct() {
+        let leg = |f: &str, t: &str, a: &str| Leg {
+            from: f.into(), to: t.into(), airway: a.into(), dist_nm: 10.0,
+        };
+        // A UN867 W UM184 B → drop W → A DCT B (can't stay on one airway).
+        let legs = vec![leg("A", "W", "UN867"), leg("W", "B", "UM184")];
+        let drop = std::collections::HashSet::from(["W".to_owned()]);
+        let out = drop_designators(&legs, &drop);
+        assert_eq!(out.len(), 1);
+        assert_eq!((out[0].from.as_str(), out[0].airway.as_str(), out[0].to.as_str()), ("A", "DCT", "B"));
     }
 
     /// A mock validator that replays a scripted sequence of verdicts, so we can

crates/core/src/routing/mod.rs

@@ -182,8 +182,11 @@ fn resolve_conn(rg: &RouteGraph, idents: &[String], near: LatLon) -> Option<Vec<
 /// Filtering airways to the cruise FL yields an IFPS-coherent route, but on some
 /// pairs the upper network is fragmented and forces an absurd detour; the full
 /// network gives the short route but may cite airways invalid at the FL. So we
-/// compute both and keep the FL-valid one unless it detours by >60 %.
+/// compute both and keep the FL-valid one only when it's near-shortest — a bigger
-const FL_ROUTE_MAX_RATIO: f64 = 1.6;
+/// detour means the FL graph fragmented (e.g. a short low-level pair whose direct
+/// airways cap at FL195), so we take the short route and let the oracle's PROF195
+/// repair lower the cruise level to where those airways are valid.
+const FL_ROUTE_MAX_RATIO: f64 = 1.25;
 
 /// Best airway route: FL-filtered when it doesn't detour too much, else full.
 pub fn plan_route_best(
@@ -208,6 +211,31 @@ pub fn plan_route_best(
     }
 }
 
+/// The highest cruise FL at which every airway leg of `route` stays valid — the
+/// min `top_fl` over its bounded airway segments (DCT/unlimited legs ignored).
+/// `None` when nothing constrains it. Lets the planner file a short low-level
+/// route (whose conventional airways cap at, e.g., FL195) at a coherent level
+/// instead of an optimistic FL360 that every leg would reject with `PROF195`.
+pub fn route_fl_ceiling(conn: &Connection, route: &Route) -> Result<Option<i32>> {
+    let mut stmt = conn.prepare(
+        "SELECT MAX(top_fl) FROM airway_segments \
+         WHERE airway_name = ?1 AND top_fl > 0 \
+           AND ((from_ident = ?2 AND to_ident = ?3) OR (from_ident = ?3 AND to_ident = ?2))",
+    )?;
+    let mut ceiling: Option<i32> = None;
+    for leg in &route.legs {
+        if leg.airway == "DCT" || leg.airway.is_empty() {
+            continue;
+        }
+        let top: Option<i32> =
+            stmt.query_row(params![leg.airway, leg.from, leg.to], |r| r.get::<_, Option<i32>>(0))?;
+        if let Some(t) = top {
+            ceiling = Some(ceiling.map_or(t, |c| c.min(t)));
+        }
+    }
+    Ok(ceiling)
+}
+
 /// The route to file for modern European airspace, in preference order:
 /// 1. FRA **graph** (published Annex-2 directs), 2. FRA heuristic (great-circle
 /// anchors), 3. airway routing. `dep_sid`/`dest_star` are (procedure, fix) pairs.