Add Remove Small Moves script

2026-04-10 09:19:32 -04:00
parent 5c6f2e2787
commit 0d222b0231
2 changed files with 212 additions and 0 deletions
--- a/Moves/README.md
+++ b/Moves/README.md
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+# GCode Small-Move Remover
+
+PowerShell script that removes gcode cutting moves where X and Y coordinates differ from the previous kept position by less than or equal to a configurable threshold (default 0.0006). These near-zero moves cause Komo CNC machines to throw `ERROR: CRC Fault`.
+
+## Problem
+
+Komo controllers reject cutting moves where the actual displacement in X and Y is negligibly small. For example:
+
+```
+N7633 G1 X23.1756 Y27.9265 Z0.7700 F150.
+N7634 G1 X23.1757 Y27.9268 Z0.7700 F150.  <-- dX=0.0001, dY=0.0003 (CRC Fault)
+N7635 G1 X23.1962 Y27.9797 Z0.7700 F150.
+N7636 G1 X23.1963 Y27.9799 Z0.7700 F150.  <-- dX=0.0001, dY=0.0002 (CRC Fault)
+N7637 G1 X23.2163 Y28.0330 Z0.7700 F150.
+```
+
+Lines N7634 and N7636 move less than 0.0006 in both X and Y from the previous position, which Komo sees as invalid and halts with a CRC Fault error.
+
+## Solution
+
+The script parses `.OUT` gcode files and removes cutting move lines (G1, G2, G3) where **both** X and Y differ from the last kept position by less than or equal to the threshold, **and** there is no Z change. This eliminates the CRC Fault triggers while preserving all meaningful toolpath data.
+
+### What gets removed
+
+- G1/G2/G3 lines where dX <= threshold AND dY <= threshold AND Z is unchanged
+
+### What is always kept
+
+- **Z moves** - any line where Z changed is never removed
+- **G0 (rapid)** positioning lines
+- **G28** (home return) lines
+- **G52** (coordinate offset) lines
+- **M-codes**, comments, tool changes, and all other non-cutting lines
+
+## Usage
+
+```powershell
+# Basic - creates *_cleaned.OUT next to the original
+.\Remove-SmallMoves.ps1 -InputFile "C:\path\to\file.OUT"
+
+# Specify output file
+.\Remove-SmallMoves.ps1 -InputFile "file.OUT" -OutputFile "file_fixed.OUT"
+
+# Custom threshold
+.\Remove-SmallMoves.ps1 -InputFile "file.OUT" -Threshold 0.001
+```
+
+## Parameters
+
+| Parameter   | Required | Default | Description |
+|-------------|----------|---------|-------------|
+| `InputFile` | Yes      | -       | Path to the input gcode file |
+| `OutputFile`| No       | `*_cleaned.OUT` | Path for the cleaned output file |
+| `Threshold` | No       | `0.0006`| Max X or Y difference for removal |
+
+## Example Output
+
+```
+GCode Small-Move Remover
+========================
+Threshold: <= 0.0006 in both X and Y
+Input:      file.OUT (8864 lines)
+Output:     file_cleaned.OUT (8310 lines)
+Removed:    554 lines
+
+Sample removed lines (first 20):
+  Line 36 removed: X=28.0339 Y=25.8585 Z=0.77 (dX=0.0002, dY=0.0003, dZ=0)
+  Line 47 removed: X=27.7644 Y=27.1713 Z=0.77 (dX=0, dY=0, dZ=0)
+  ...
+```
+
+## How It Works
+
+1. Reads the input file line by line
+2. Extracts X, Y, Z coordinates using regex
+3. For cutting moves (G1/G2/G3) only:
+   - If Z changed significantly (> 0.0001), the line is always kept
+   - If Z is the same, compares X and Y against the last kept position
+   - If both dX and dY are within threshold, the line is removed
+4. Updates the last known X/Y/Z position from kept lines only (removed lines don't update position tracking)
--- a/Moves/Remove-SmallMoves.ps1
+++ b/Moves/Remove-SmallMoves.ps1
@@ -0,0 +1,132 @@
+<#
+.SYNOPSIS
+    Removes gcode lines where X and Y coordinates differ from the previous
+    kept line by <= Threshold (default 0.0006), which causes Komo CRC Fault errors.
+
+.DESCRIPTION
+    Parses a gcode .OUT file and removes movement lines where both the X and Y
+    differences from the last kept position are within the threshold AND there
+    is no significant Z change. Lines with Z moves are always kept.
+    This eliminates near-zero XY moves that trigger Komo ERROR: CRC Fault.
+
+    Only cutting moves (G1, G2, G3) are candidates for removal. All other lines
+    including G0 (rapid), G28 (home), G52 (offset), M-codes, and comments are
+    always kept unchanged.
+
+.PARAMETER InputFile
+    Path to the input gcode file.
+
+.PARAMETER OutputFile
+    Path for the cleaned output file. Defaults to input filename with "_cleaned"
+    appended before the extension.
+
+.PARAMETER Threshold
+    Maximum X or Y difference to consider a line for removal. Default 0.0006.
+
+.EXAMPLE
+    .\Remove-SmallMoves.ps1 "C:\path\to\file.OUT"
+    .\Remove-SmallMoves.ps1 -InputFile "file.OUT" -OutputFile "file_fixed.OUT" -Threshold 0.001
+#>
+
+param(
+    [Parameter(Mandatory = $true)]
+    [string]$InputFile,
+
+    [string]$OutputFile,
+
+    [double]$Threshold = 0.0006
+)
+
+if (-not $OutputFile) {
+    $OutputFile = [System.IO.Path]::Combine(
+        [System.IO.Path]::GetDirectoryName($InputFile),
+        [System.IO.Path]::GetFileNameWithoutExtension($InputFile) + '_cleaned' + [System.IO.Path]::GetExtension($InputFile)
+    )
+}
+
+$lines = Get-Content $InputFile
+
+$lastX = $null
+$lastY = $null
+$lastZ = $null
+$removedLines = [System.Collections.ArrayList]::new()
+$result = [System.Collections.ArrayList]::new()
+$removedCount = 0
+$lineNum = 0
+
+foreach ($line in $lines) {
+    $lineNum++
+
+    $xMatch = [regex]::Match($line, 'X(-?\d+\.?\d*)')
+    $yMatch = [regex]::Match($line, 'Y(-?\d+\.?\d*)')
+    $zMatch = [regex]::Match($line, 'Z(-?\d+\.?\d*)')
+
+    $hasX = $xMatch.Success
+    $hasY = $yMatch.Success
+    $hasZ = $zMatch.Success
+
+    if (-not ($hasX -or $hasY -or $hasZ)) {
+        [void]$result.Add($line)
+        continue
+    }
+
+    $isCuttingMove = $line -match '\bG[123]\b'
+
+    if (-not $isCuttingMove) {
+        if ($hasX) { $lastX = $x }
+        if ($hasY) { $lastY = $y }
+        if ($hasZ) { $lastZ = $z }
+        [void]$result.Add($line)
+        continue
+    }
+
+    $x = if ($hasX) { [double]::Parse($xMatch.Groups[1].Value, [System.Globalization.CultureInfo]::InvariantCulture) } else { $lastX }
+    $y = if ($hasY) { [double]::Parse($yMatch.Groups[1].Value, [System.Globalization.CultureInfo]::InvariantCulture) } else { $lastY }
+    $z = if ($hasZ) { [double]::Parse($zMatch.Groups[1].Value, [System.Globalization.CultureInfo]::InvariantCulture) } else { $lastZ }
+
+    if ($null -ne $lastZ -and $null -ne $z) {
+        $diffZ = [math]::Abs($z - $lastZ)
+    } else {
+        $diffZ = [double]::MaxValue
+    }
+
+    if ($diffZ -lt 0.0001) {
+        if ($null -ne $lastX -and $null -ne $lastY -and $null -ne $x -and $null -ne $y) {
+            $diffX = [math]::Abs($x - $lastX)
+            $diffY = [math]::Abs($y - $lastY)
+
+            if ($diffX -le $Threshold -and $diffY -le $Threshold) {
+                [void]$removedLines.Add("Line $lineNum removed: X=${x} Y=${y} Z=${z} (dX=$diffX, dY=$diffY, dZ=$diffZ)")
+                $removedCount++
+                continue
+            }
+        }
+    }
+
+    if ($hasX) { $lastX = $x }
+    if ($hasY) { $lastY = $y }
+    if ($hasZ) { $lastZ = $z }
+    [void]$result.Add($line)
+}
+
+$result | Set-Content $OutputFile
+
+Write-Host ""
+Write-Host "GCode Small-Move Remover"
+Write-Host "========================"
+Write-Host "Threshold: <= $Threshold in both X and Y"
+Write-Host "Input:      $InputFile ($($lines.Count) lines)"
+Write-Host "Output:     $OutputFile ($($result.Count) lines)"
+Write-Host "Removed:    $removedCount lines"
+Write-Host ""
+
+if ($removedLines.Count -gt 0) {
+    Write-Host "Sample removed lines (first 20):"
+    $sample = if ($removedLines.Count -gt 20) { $removedLines[0..19] } else { $removedLines }
+    foreach ($r in $sample) {
+        Write-Host "  $r"
+    }
+    if ($removedLines.Count -gt 20) {
+        Write-Host "  ... and $($removedLines.Count - 20) more"
+    }
+}