feat: Enhance authentication middleware and token refresh logic with improved caching, retry mechanisms, and error handling

server/api/expenses/generate-pdf.ts

@@ -655,9 +655,6 @@ async function addReceiptImages(doc: PDFKit.PDFDocument, expenses: Expense[]) {
 
 async function fetchReceiptImage(receipt: any): Promise<Buffer | null> {
   try {
-    const client = getMinioClient();
-    const bucketName = useRuntimeConfig().minio.bucketName;
-    
     // Determine the file path - try multiple possible sources
     let rawPath = null;
     
@@ -683,7 +680,70 @@ async function fetchReceiptImage(receipt: any): Promise<Buffer | null> {
     
     console.log('[expenses/generate-pdf] Raw path from receipt:', rawPath);
     
-    // Extract MinIO path from S3 URL or use as-is if it's already a path
+    // Check if this is an S3 URL (HTTP/HTTPS)
+    if (rawPath.startsWith('http://') || rawPath.startsWith('https://')) {
+      console.log('[expenses/generate-pdf] Detected S3 URL, fetching directly...');
+      
+      try {
+        // Fetch image directly from S3 URL
+        const response = await fetch(rawPath, {
+          method: 'GET',
+          headers: {
+            'Accept': 'image/*'
+          },
+          // Add timeout to prevent hanging
+          signal: AbortSignal.timeout(30000) // 30 second timeout
+        });
+        
+        if (!response.ok) {
+          console.error(`[expenses/generate-pdf] Failed to fetch image from S3: ${response.status} ${response.statusText}`);
+          return null;
+        }
+        
+        // Convert response to buffer
+        const arrayBuffer = await response.arrayBuffer();
+        const imageBuffer = Buffer.from(arrayBuffer);
+        
+        console.log('[expenses/generate-pdf] Successfully fetched image from S3 URL, Size:', imageBuffer.length);
+        return imageBuffer;
+        
+      } catch (fetchError: any) {
+        console.error('[expenses/generate-pdf] Error fetching from S3 URL:', fetchError.message);
+        
+        // If it's a timeout, try once more with a longer timeout
+        if (fetchError.name === 'TimeoutError' || fetchError.name === 'AbortError') {
+          console.log('[expenses/generate-pdf] Retrying with longer timeout...');
+          try {
+            const retryResponse = await fetch(rawPath, {
+              method: 'GET',
+              headers: {
+                'Accept': 'image/*'
+              },
+              signal: AbortSignal.timeout(60000) // 60 second timeout for retry
+            });
+            
+            if (retryResponse.ok) {
+              const arrayBuffer = await retryResponse.arrayBuffer();
+              const imageBuffer = Buffer.from(arrayBuffer);
+              console.log('[expenses/generate-pdf] Successfully fetched image on retry, Size:', imageBuffer.length);
+              return imageBuffer;
+            }
+          } catch (retryError) {
+            console.error('[expenses/generate-pdf] Retry also failed:', retryError);
+          }
+        }
+        
+        return null;
+      }
+    }
+    
+    // If not an S3 URL, try MinIO as fallback
+    console.log('[expenses/generate-pdf] Not an S3 URL, trying MinIO fallback...');
+    
+    const client = getMinioClient();
+    const bucketName = useRuntimeConfig().minio.bucketName;
+    
+    // Extract MinIO path from the raw path
     let minioPath = extractMinioPath(rawPath);
     
     if (!minioPath) {