Overhaul infrastructure: replace GPU model with rack-centric system

Replace flat GPU buying with a realistic data center + rack pipeline:
- 4 DC tiers (small/medium/large/mega) with construction time, dual
  capacity constraints (rack slots + power budget kW), and era/research
  gating
- 10 predefined rack SKUs from consumer GPUs through custom ASICs, each
  with unique FLOPS, power draw, cost, and pipeline timings
- 6-stage procurement pipeline (order → mfg → receive → install → test
  → production) with Kanban UI, talent-influenced speed bonuses
- Test failures (5-25% base rate) reduced by cooling, ops talent, and QA
  research; auto-repair with cost and re-test cycle
- Production failures at low per-tick rate, racks sent to repair pipeline
- Cooling and redundancy upgrades per DC (reduce failure rates)
- 4 new tech tree nodes (DC Engineering II/III/IV, Quality Assurance)
- Save version bump (1→2) with migration that resets old saves
- Updated economy system to account for rack repair costs
- Redesigned Infrastructure page with pipeline Kanban, capacity bars,
  rack ordering, and DC upgrade panels

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

packages/game-engine/src/data/achievements.ts

@@ -79,11 +79,11 @@ export const ACHIEVEMENT_DEFINITIONS: AchievementDefinition[] = [
     condition: { field: 'meta._eraIndex', operator: 'gte', value: 3 },
   },
   {
-    id: 'gpu-hoarder',
-    name: 'GPU Hoarder',
-    description: 'Own 100 or more GPUs across all data centers.',
+    id: 'rack-hoarder',
+    name: 'Rack Hoarder',
+    description: 'Have 50 or more production racks across all data centers.',
     icon: 'Cpu',
-    condition: { field: 'infrastructure._totalGpuCount', operator: 'gte', value: 100 },
+    condition: { field: 'infrastructure.totalRackCount', operator: 'gte', value: 50 },
   },
   {
     id: 'research-pioneer',

packages/game-engine/src/data/techTree.ts

@@ -25,32 +25,32 @@ export const TECH_TREE: ResearchNode[] = [
   {
     id: 'advanced-gpu-arch',
     name: 'Advanced GPU Architecture',
-    description: 'Unlocks procurement of NVIDIA A100 datacenter GPUs.',
+    description: 'Unlocks procurement of NVIDIA A100 rack configurations.',
     era: 'startup',
     category: 'infrastructure',
     prerequisites: [],
     cost: { researchPoints: 0, compute: 10, ticks: 90 },
-    effects: [{ type: 'unlock_gpu', target: 'a100', value: 1 }],
+    effects: [{ type: 'unlock_rack', target: 'a100', value: 1 }],
   },
   {
     id: 'next-gen-gpu',
     name: 'Next-Gen GPU Architecture',
-    description: 'Unlocks procurement of NVIDIA H100 GPUs.',
+    description: 'Unlocks procurement of NVIDIA H100 rack configurations.',
     era: 'scaleup',
     category: 'infrastructure',
     prerequisites: ['advanced-gpu-arch'],
     cost: { researchPoints: 2, compute: 40, ticks: 240 },
-    effects: [{ type: 'unlock_gpu', target: 'h100', value: 1 }],
+    effects: [{ type: 'unlock_rack', target: 'h100', value: 1 }],
   },
   {
     id: 'frontier-compute',
     name: 'Frontier Compute',
-    description: 'Unlocks procurement of NVIDIA B200 GPUs.',
+    description: 'Unlocks procurement of NVIDIA B200 rack configurations.',
     era: 'bigtech',
     category: 'infrastructure',
     prerequisites: ['next-gen-gpu'],
     cost: { researchPoints: 5, compute: 200, ticks: 480 },
-    effects: [{ type: 'unlock_gpu', target: 'b200', value: 1 }],
+    effects: [{ type: 'unlock_rack', target: 'b200', value: 1 }],
   },
   {
     id: 'custom-silicon',
@@ -60,7 +60,47 @@ export const TECH_TREE: ResearchNode[] = [
     category: 'infrastructure',
     prerequisites: ['frontier-compute'],
     cost: { researchPoints: 10, compute: 500, ticks: 900 },
-    effects: [{ type: 'unlock_gpu', target: 'custom', value: 1 }],
+    effects: [{ type: 'unlock_rack', target: 'custom', value: 1 }],
+  },
+  {
+    id: 'dc-engineering-ii',
+    name: 'DC Engineering II',
+    description: 'Advanced facility design unlocks Medium data centers (30 slots, 200kW).',
+    era: 'startup',
+    category: 'infrastructure',
+    prerequisites: ['advanced-cooling'],
+    cost: { researchPoints: 1, compute: 15, ticks: 120 },
+    effects: [{ type: 'unlock_dc_tier', target: 'medium', value: 1 }],
+  },
+  {
+    id: 'dc-engineering-iii',
+    name: 'DC Engineering III',
+    description: 'Large-scale facility design unlocks Large data centers (60 slots, 500kW).',
+    era: 'scaleup',
+    category: 'infrastructure',
+    prerequisites: ['dc-engineering-ii'],
+    cost: { researchPoints: 3, compute: 60, ticks: 300 },
+    effects: [{ type: 'unlock_dc_tier', target: 'large', value: 1 }],
+  },
+  {
+    id: 'dc-engineering-iv',
+    name: 'DC Engineering IV',
+    description: 'Mega-scale campus design unlocks Mega data centers (120 slots, 1200kW).',
+    era: 'bigtech',
+    category: 'infrastructure',
+    prerequisites: ['dc-engineering-iii'],
+    cost: { researchPoints: 6, compute: 150, ticks: 600 },
+    effects: [{ type: 'unlock_dc_tier', target: 'mega', value: 1 }],
+  },
+  {
+    id: 'quality-assurance',
+    name: 'Quality Assurance',
+    description: 'Advanced QA processes reduce rack test failure rate by 25%.',
+    era: 'startup',
+    category: 'infrastructure',
+    prerequisites: ['redundancy-protocols'],
+    cost: { researchPoints: 1, compute: 10, ticks: 90 },
+    effects: [{ type: 'cost_reduction', target: 'test_failure_rate', value: 0.25 }],
   },
   {
     id: 'distributed-training',

packages/game-engine/src/systems/achievementSystem.ts

@@ -10,12 +10,6 @@ const ERA_INDEX: Record<string, number> = { startup: 0, scaleup: 1, bigtech: 2,
 function getFieldValue(state: GameState, field: string): number {
   if (field === 'meta._eraIndex') return ERA_INDEX[state.meta.currentEra] ?? 0;
   if (field === 'meta._deployedModelCount') return state.models.trainedModels.filter(m => m.isDeployed).length;
-  if (field === 'infrastructure._totalGpuCount') {
-    return state.infrastructure.dataCenters.reduce(
-      (sum, dc) => sum + dc.gpus.reduce((s, g) => s + g.count, 0), 0,
-    );
-  }
-
   const parts = field.split('.');
   let current: unknown = state;
   for (const part of parts) {

packages/game-engine/src/systems/economySystem.ts

@@ -6,6 +6,7 @@ export function processEconomy(
   state: GameState,
   market: MarketTickResult,
   infrastructure: InfrastructureState,
+  extraCosts: number = 0,
 ): EconomyState {
   const revenue = market.apiRevenue + market.subscriptionRevenue;
 
@@ -20,7 +21,7 @@ export function processEconomy(
   const eraIdx = ['startup', 'scaleup', 'bigtech', 'agi'].indexOf(state.meta.currentEra);
   const complianceCost = bestCapability > 30 ? bestCapability * REGULATION_COMPLIANCE_PER_CAPABILITY * (1 + eraIdx * 0.5) / 100 : 0;
 
-  const expenses = infraExpenses + talentExpenses + dataExpenses + complianceCost;
+  const expenses = infraExpenses + talentExpenses + dataExpenses + complianceCost + extraCosts;
 
   const money = state.economy.money + revenue - expenses;
 

packages/game-engine/src/systems/infrastructureSystem.ts

@@ -1,72 +1,275 @@
-import type { GameState, InfrastructureState } from '@ai-tycoon/shared';
+import type { GameState, InfrastructureState, DataCenter, RackOrder, Rack, PipelineStage } from '@ai-tycoon/shared';
 import {
-  GPU_CONFIGS,
   LOCATION_CONFIGS,
-  GPU_PRICE_VOLATILITY,
-  GPU_FAILURE_RATE_BASE,
-  REDUNDANCY_FAILURE_REDUCTION,
+  RACK_SKU_CONFIGS,
+  DC_TIER_CONFIGS,
   BASE_ENERGY_COST_PER_FLOP,
-  BASE_MAINTENANCE_PER_GPU,
+  BASE_MAINTENANCE_PER_RACK,
+  COOLING_FAILURE_REDUCTION,
+  REDUNDANCY_FAILURE_REDUCTION,
+  RACK_REPAIR_BASE_TICKS,
 } from '@ai-tycoon/shared';
-import type { GpuType } from '@ai-tycoon/shared';
+import type { TickNotification } from '../tick';
 
-export function processInfrastructure(state: GameState): InfrastructureState {
-  const dataCenters = state.infrastructure.dataCenters.map(dc => {
-    const location = LOCATION_CONFIGS[dc.location];
+export interface InfraTickResult {
+  infrastructure: InfrastructureState;
+  notifications: TickNotification[];
+  repairCosts: number;
+}
 
-    const gpus = dc.gpus.map(inv => {
-      const failureRate = GPU_FAILURE_RATE_BASE * (1 - dc.redundancyLevel * REDUNDANCY_FAILURE_REDUCTION);
-      let newFailed = inv.failedCount;
-      for (let i = 0; i < inv.healthyCount; i++) {
-        if (Math.random() < failureRate) newFailed++;
-      }
-      const healthyCount = Math.max(0, inv.count - newFailed);
-      return { ...inv, healthyCount, failedCount: newFailed };
-    });
+const PIPELINE_ADVANCE_ORDER: PipelineStage[] = [
+  'ordered', 'manufacturing', 'receiving', 'installation', 'testing',
+];
 
-    let totalFlops = 0;
-    let totalPower = 0;
-    let totalGpuCount = 0;
-    for (const inv of gpus) {
-      const config = GPU_CONFIGS[inv.type];
-      totalFlops += inv.healthyCount * config.flopsPerUnit;
-      totalPower += inv.healthyCount * config.basePowerDraw;
-      totalGpuCount += inv.count;
+function nextStage(stage: PipelineStage): PipelineStage | 'production' {
+  const idx = PIPELINE_ADVANCE_ORDER.indexOf(stage);
+  if (idx === -1 || idx === PIPELINE_ADVANCE_ORDER.length - 1) return 'production';
+  return PIPELINE_ADVANCE_ORDER[idx + 1];
+}
+
+function stageTotal(stage: PipelineStage, order: RackOrder): number {
+  const sku = RACK_SKU_CONFIGS[order.skuId];
+  const timings = sku.pipelineTimeTicks;
+  switch (stage) {
+    case 'manufacturing': return timings.manufacturing;
+    case 'receiving': return timings.receiving;
+    case 'installation': return timings.installation;
+    case 'testing': return timings.testing;
+    case 'repair': return RACK_REPAIR_BASE_TICKS;
+    default: return 0;
+  }
+}
+
+function stageSpeed(stage: PipelineStage, engEff: number, opsEff: number): number {
+  switch (stage) {
+    case 'manufacturing': return 1 + engEff * 0.1;
+    case 'installation':
+    case 'testing': return 1 + opsEff * 0.1;
+    case 'repair': return 1 + opsEff * 0.05;
+    default: return 1;
+  }
+}
+
+export function processInfrastructure(state: GameState): InfraTickResult {
+  const notifications: TickNotification[] = [];
+  let repairCosts = 0;
+
+  const engEff = state.talent.departments.engineering.effectiveness;
+  const opsEff = state.talent.departments.operations.effectiveness;
+
+  const qaResearchBonus = state.research.completedResearch.includes('quality-assurance') ? 0.25 : 0;
+
+  // --- Phase 1: Advance DC Construction ---
+  const dataCenters: DataCenter[] = state.infrastructure.dataCenters.map(dc => {
+    if (dc.status !== 'constructing') return { ...dc };
+
+    const newProgress = dc.constructionProgress + 1;
+    if (newProgress >= dc.constructionTotal) {
+      notifications.push({
+        title: 'Data Center Online',
+        message: `${dc.name} is now operational!`,
+        type: 'success',
+      });
+      return { ...dc, constructionProgress: dc.constructionTotal, status: 'operational' as const };
     }
-
-    const energyCostPerTick = totalPower * BASE_ENERGY_COST_PER_FLOP * location.energyCostMultiplier;
-    const maintenanceCostPerTick = totalGpuCount * BASE_MAINTENANCE_PER_GPU;
-    const currentUptime = totalGpuCount > 0
-      ? gpus.reduce((s, inv) => s + inv.healthyCount, 0) / totalGpuCount
-      : 1;
-
-    return { ...dc, gpus, energyCostPerTick, maintenanceCostPerTick, currentUptime };
+    return { ...dc, constructionProgress: newProgress };
   });
 
-  const gpuMarketPrices = { ...state.infrastructure.gpuMarketPrices };
-  for (const gpuType of Object.keys(gpuMarketPrices) as GpuType[]) {
-    const basePrice = GPU_CONFIGS[gpuType].basePrice;
-    const variation = (Math.random() - 0.5) * 2 * GPU_PRICE_VOLATILITY;
-    const currentPrice = gpuMarketPrices[gpuType];
-    const newPrice = currentPrice * (1 + variation);
-    gpuMarketPrices[gpuType] = Math.max(basePrice * 0.7, Math.min(basePrice * 1.5, newPrice));
+  // --- Phase 2: Advance Rack Pipeline ---
+  const rackPipeline: RackOrder[] = [];
+  const newRacks: Rack[] = [];
+
+  for (const order of state.infrastructure.rackPipeline) {
+    const speed = stageSpeed(order.stage, engEff, opsEff);
+    const newProgress = order.stageProgress + speed;
+
+    if (newProgress < order.stageTotal) {
+      rackPipeline.push({ ...order, stageProgress: newProgress });
+      continue;
+    }
+
+    if (order.stage === 'repair') {
+      const total = stageTotal('testing', order);
+      rackPipeline.push({
+        ...order,
+        stage: 'testing',
+        stageProgress: 0,
+        stageTotal: total,
+      });
+      continue;
+    }
+
+    const next = nextStage(order.stage);
+
+    if (next === 'production') {
+      const sku = RACK_SKU_CONFIGS[order.skuId];
+      const dc = dataCenters.find(d => d.id === order.dataCenterId);
+      const cooling = dc?.coolingLevel ?? 0;
+
+      const effectiveFailRate = sku.testFailureRate
+        * (1 - cooling * COOLING_FAILURE_REDUCTION)
+        * (1 - opsEff * 0.2)
+        * (1 - qaResearchBonus);
+
+      if (Math.random() < effectiveFailRate) {
+        const repairCost = sku.baseCost * sku.repairCostFraction;
+        repairCosts += repairCost;
+        rackPipeline.push({
+          ...order,
+          stage: 'repair',
+          stageProgress: 0,
+          stageTotal: RACK_REPAIR_BASE_TICKS,
+          repairCount: order.repairCount + 1,
+        });
+        notifications.push({
+          title: 'Rack Failed Testing',
+          message: `${sku.name} rack failed QA (attempt ${order.repairCount + 1}). Repair cost: $${repairCost.toLocaleString()}`,
+          type: 'warning',
+        });
+      } else {
+        newRacks.push({
+          id: order.id,
+          skuId: order.skuId,
+          dataCenterId: order.dataCenterId,
+          isHealthy: true,
+        });
+        notifications.push({
+          title: 'Rack Online',
+          message: `${sku.name} rack is now in production at ${dc?.name ?? 'data center'}.`,
+          type: 'success',
+        });
+      }
+    } else {
+      const total = stageTotal(next, order);
+      rackPipeline.push({
+        ...order,
+        stage: next,
+        stageProgress: 0,
+        stageTotal: total,
+      });
+    }
   }
 
+  // Add newly completed racks to their data centers
+  for (const rack of newRacks) {
+    const dcIdx = dataCenters.findIndex(d => d.id === rack.dataCenterId);
+    if (dcIdx !== -1) {
+      dataCenters[dcIdx] = {
+        ...dataCenters[dcIdx],
+        racks: [...dataCenters[dcIdx].racks, rack],
+      };
+    }
+  }
+
+  // --- Phase 3: Production Failures ---
+  for (let dcIdx = 0; dcIdx < dataCenters.length; dcIdx++) {
+    const dc = dataCenters[dcIdx];
+    if (dc.status !== 'operational') continue;
+
+    const updatedRacks: Rack[] = [];
+    for (const rack of dc.racks) {
+      if (!rack.isHealthy) {
+        updatedRacks.push(rack);
+        continue;
+      }
+
+      const sku = RACK_SKU_CONFIGS[rack.skuId];
+      const effectiveRate = sku.productionFailureRate
+        * (1 - dc.coolingLevel * COOLING_FAILURE_REDUCTION)
+        * (1 - dc.redundancyLevel * REDUNDANCY_FAILURE_REDUCTION);
+
+      if (Math.random() < effectiveRate) {
+        updatedRacks.push({ ...rack, isHealthy: false });
+        const repairCost = sku.baseCost * sku.repairCostFraction;
+        repairCosts += repairCost;
+
+        rackPipeline.push({
+          id: rack.id,
+          skuId: rack.skuId,
+          dataCenterId: dc.id,
+          stage: 'repair',
+          stageProgress: 0,
+          stageTotal: RACK_REPAIR_BASE_TICKS,
+          totalCost: repairCost,
+          repairCount: 0,
+        });
+
+        notifications.push({
+          title: 'Rack Failure',
+          message: `${sku.name} rack failed in ${dc.name}. Sent for repair.`,
+          type: 'danger',
+        });
+      } else {
+        updatedRacks.push(rack);
+      }
+    }
+
+    // Remove failed racks from the DC (they're now in the repair pipeline)
+    dataCenters[dcIdx] = {
+      ...dc,
+      racks: updatedRacks.filter(r => r.isHealthy),
+    };
+  }
+
+  // --- Phase 4: Compute Aggregates ---
   let totalFlops = 0;
   let totalUptime = 0;
-  let dcCount = 0;
-  for (const dc of dataCenters) {
-    for (const inv of dc.gpus) {
-      totalFlops += inv.healthyCount * GPU_CONFIGS[inv.type].flopsPerUnit;
+  let totalRackCount = 0;
+  let dcWithRacks = 0;
+
+  for (let dcIdx = 0; dcIdx < dataCenters.length; dcIdx++) {
+    const dc = dataCenters[dcIdx];
+    if (dc.status !== 'operational') continue;
+
+    const location = LOCATION_CONFIGS[dc.location];
+    const tierConfig = DC_TIER_CONFIGS[dc.tier];
+
+    let dcFlops = 0;
+    let usedPowerKW = 0;
+    const healthyCount = dc.racks.length;
+    const totalInDc = dc.racks.length;
+
+    for (const rack of dc.racks) {
+      const sku = RACK_SKU_CONFIGS[rack.skuId];
+      dcFlops += sku.flopsPerRack;
+      usedPowerKW += sku.powerDrawKW;
     }
-    totalUptime += dc.currentUptime;
-    dcCount++;
+
+    const pipelineRacksForDc = rackPipeline.filter(o => o.dataCenterId === dc.id).length;
+    const usedSlots = totalInDc + pipelineRacksForDc;
+
+    const energyCostPerTick = (tierConfig.baseEnergyCostPerTick + usedPowerKW * BASE_ENERGY_COST_PER_FLOP)
+      * location.energyCostMultiplier;
+    const maintenanceCostPerTick = totalInDc * BASE_MAINTENANCE_PER_RACK;
+
+    const currentUptime = totalInDc > 0 ? healthyCount / totalInDc : 1;
+
+    totalFlops += dcFlops;
+    totalRackCount += totalInDc;
+    if (totalInDc > 0) {
+      totalUptime += currentUptime;
+      dcWithRacks++;
+    }
+
+    dataCenters[dcIdx] = {
+      ...dataCenters[dcIdx],
+      usedSlots,
+      usedPowerKW,
+      energyCostPerTick,
+      maintenanceCostPerTick,
+      currentUptime,
+    };
   }
 
   return {
-    dataCenters,
-    gpuMarketPrices,
-    totalFlops,
-    totalUptime: dcCount > 0 ? totalUptime / dcCount : 1,
+    infrastructure: {
+      dataCenters,
+      rackPipeline,
+      totalFlops,
+      totalUptime: dcWithRacks > 0 ? totalUptime / dcWithRacks : 1,
+      totalRackCount,
+    },
+    notifications,
+    repairCosts,
   };
 }

packages/game-engine/src/tick.ts

@@ -39,7 +39,9 @@ export function setAchievementDefinitions(defs: AchievementDefinition[]) {
 export function processTick(state: GameState): Partial<GameState> {
   const notifications: TickNotification[] = [];
 
-  const infrastructure = processInfrastructure(state);
+  const infraResult = processInfrastructure(state);
+  const infrastructure = infraResult.infrastructure;
+  notifications.push(...infraResult.notifications);
 
   const stateWithInfra = { ...state, infrastructure };
   const modelResult = processModels(stateWithInfra);
@@ -82,7 +84,7 @@ export function processTick(state: GameState): Partial<GameState> {
       type: 'danger',
     });
   }
-  const economy = processEconomy(stateWithTalent, market, infrastructure);
+  const economy = processEconomy(stateWithTalent, market, infrastructure, infraResult.repairCosts);
   const data = processData(stateWithTalent);
   const competitors = processCompetitors(stateWithTalent);