catalog/model/extension/shipping/usps.php

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<?php
class ModelExtensionShippingUsps extends Model {
	public function getQuote($address) {
		$this->load->language('extension/shipping/usps');

		$query = $this->db->query("SELECT * FROM " . DB_PREFIX . "zone_to_geo_zone WHERE geo_zone_id = '" . (int)$this->config->get('shipping_usps_geo_zone_id') . "' AND country_id = '" . (int)$address['country_id'] . "' AND (zone_id = '" . (int)$address['zone_id'] . "' OR zone_id = '0')");

		if (!$this->config->get('shipping_usps_geo_zone_id')) {
			$status = true;
		} elseif ($query->num_rows) {
			$status = true;
		} else {
			$status = false;
		}

		$weight = $this->weight->convert($this->cart->getWeight(), $this->config->get('config_weight_class_id'), $this->config->get('shipping_usps_weight_class_id'));
		
		// 70 pound limit
		if ($weight > 70) {
			$status = false;
		}

		$method_data = array();

		if ($status) {
			$this->load->model('localisation/country');

			$quote_data = array();

			$weight = ($weight < 0.1 ? 0.1 : $weight);
			$pounds = floor($weight);
			$ounces = round(16 * ($weight - $pounds), 2); // max 5 digits

			$postcode = str_replace(' ', '', $address['postcode']);

			if ($address['iso_code_2'] == 'US') {
				$xml  = '<RateV4Request USERID="' . $this->config->get('shipping_usps_user_id') . '">';
				$xml .= '	<Package ID="1">';
				$xml .=	'		<Service>ALL</Service>';
				$xml .=	'		<ZipOrigination>' . substr($this->config->get('shipping_usps_postcode'), 0, 5) . '</ZipOrigination>';
				$xml .=	'		<ZipDestination>' . substr($postcode, 0, 5) . '</ZipDestination>';
				$xml .=	'		<Pounds>' . $pounds . '</Pounds>';
				$xml .=	'		<Ounces>' . $ounces . '</Ounces>';

				// Prevent common size mismatch error from USPS (Size cannot be Regular if Container is Rectangular for some reason)
				if ($this->config->get('shipping_usps_container') == 'RECTANGULAR' && $this->config->get('shipping_usps_size') == 'REGULAR') {
					$this->config->set('shipping_usps_container', 'VARIABLE');
				}

				$xml .=	'		<Container>' . $this->config->get('shipping_usps_container') . '</Container>';
				$xml .=	'		<Size>' . $this->config->get('shipping_usps_size') . '</Size>';
				$xml .= '		<Width>' . $this->config->get('shipping_usps_width') . '</Width>';
				$xml .= '		<Length>' . $this->config->get('shipping_usps_length') . '</Length>';
				$xml .= '		<Height>' . $this->config->get('shipping_usps_height') . '</Height>';

				// Calculate girth based on usps calculation
				$xml .= '		<Girth>' . (round(((float)$this->config->get('shipping_usps_length') + (float)$this->config->get('shipping_usps_width') * 2 + (float)$this->config->get('shipping_usps_height') * 2), 1)) . '</Girth>';
				$xml .=	'		<Machinable>' . ($this->config->get('shipping_usps_machinable') ? 'true' : 'false') . '</Machinable>';
				$xml .=	'	</Package>';
				$xml .= '</RateV4Request>';