python_gcode_checker.py

import re
from decimal import Decimal, getcontext
import decimal

# Define interpolation and movement commands
interpolation_commands = {"G01", "G02", "G03"}
movement_commands = {"G00"}

# Define a pattern to recognize common G-code commands
gcode_pattern = re.compile(
    r"(G\d+|M\d+|X[-+]?\d*\.?\d+|Y[-+]?\d*\.?\d+|"
    r"Z[-+]?\d*\.?\d+|I[-+]?\d*\.?\d+|J[-+]?\d*\.?\d+|"
    r"F[-+]?\d*\.?\d+|S[-+]?\d*\.?\d+)"
)

def standardize_codes(line):
    """
    Standardizes M-codes and G-codes to two digits by adding a leading zero if necessary.
    """
    line = re.sub(r"\b(M|G)(\d)\b", r"\g<1>0\2", line)
    return line

def remove_comments(line):
    """
    Removes comments from a G-code line. Supports both ';' and '()' style comments.
    """
    # Remove anything after a ';'
    line = line.split(';')[0]
    # Remove anything inside parentheses '()'
    line = re.sub(r'\(.*?\)', '', line)
    return line.strip()

def preprocess_gcode(gcode):
    """
    Removes comments from the G-code and returns a list of tuples (original_line_number, cleaned_line).
    Includes all lines to maintain accurate line numbering.
    """
    cleaned_lines = []
    lines = gcode.splitlines()

    for idx, line in enumerate(lines):
        original_line_number = idx + 1  # Line numbers start from 1
        line = standardize_codes(line.strip())
        # Remove comments
        line_no_comments = remove_comments(line)
        # Include all lines to maintain accurate line numbering
        cleaned_lines.append((original_line_number, line_no_comments))

    return cleaned_lines

def check_required_gcodes(lines_with_numbers):
    """
    Checks that the G-code contains required G-codes: G20/G21, G90/G91, G54-G59, and G17.
    Returns a list of errors with individual entries for each missing group.
    """
    required_groups = {
        "units": {"G20", "G21"},  # Metric or Imperial Units
        "mode": {"G90", "G91"},  # Absolute or Incremental Mode
        "work_coordinates": {"G54", "G55", "G56", "G57", "G58", "G59"},  # Work Offsets
        "plane": {"G17", "G18", "G19"},  # Selected Plane
    }

    # Create a set to track found codes and their line numbers
    found_codes = {}
    for original_line_number, line in lines_with_numbers:
        tokens = line.split()
        for token in tokens:
            found_codes.setdefault(token, original_line_number)  # Record the line number where the code was found

    # List to hold individual errors for each missing group
    missing_group_errors = []
    
    # Check for presence of required codes
    for category, codes in required_groups.items():
        # Only flag as missing if both options in a group are absent
        found = any(code in found_codes for code in codes)
        if not found:
            missing_codes = "/".join(sorted(codes))
            # Assume missing codes should be on the first line where G-codes start
            for original_line_number, line in lines_with_numbers:
                if gcode_pattern.search(line):
                    missing_group_errors.append((original_line_number, f"(Error) Missing required G-codes: ({category}) {missing_codes}"))
                    break
            else:
                # Default to line 1 if no G-code commands are found
                missing_group_errors.append((1, f"(Error) Missing required G-codes: ({category}) {missing_codes}"))

    return missing_group_errors

def check_required_gcodes_position(lines_with_numbers):
    """
    Ensures required G-codes appear before movement commands.
    Flags changes in critical settings (e.g., units) after movement commands.
    """
    issues = []
    movement_seen = False
    required_groups = {
        "units": {"G20", "G21"},
        "mode": {"G90", "G91"},
        "work_coordinates": {"G54", "G55", "G56", "G57", "G58", "G59"},
        "plane": {"G17", "G18", "G19"},
    }
    critical_gcodes = {
        "units": {"G20", "G21"},
        "plane": {"G17", "G18", "G19"},
    }

    # Track codes found before movement commands
    codes_before_movement = set()

    for original_line_number, line in lines_with_numbers:
        tokens = line.split()

        # Check if movement commands are encountered
        if not movement_seen and any(cmd in tokens for cmd in {"G00", "G01", "G02", "G03"}):
            movement_seen = True

        if not movement_seen:
            # Collect required G-codes found before movement
            codes_before_movement.update(tokens)
        else:
            # After movement commands have been seen, check for critical G-codes
            for token in tokens:
                for category, codes in critical_gcodes.items():
                    if token in codes:
                        issues.append((original_line_number, f"(Warning) {token} appears after movement commands. Ensure this change is intentional -> {line.strip()}"))

    # Check for missing required G-codes before movement commands
    missing_groups = []
    for category, codes in required_groups.items():
        if not any(code in codes_before_movement for code in codes):
            missing_codes = "/".join(sorted(codes))
            missing_groups.append(f"({category}) {missing_codes}")

    if missing_groups:
        first_movement_line = next(
            (line_num for line_num, line in lines_with_numbers if any(cmd in line for cmd in {"G00", "G01", "G02", "G03"})),
            1
        )
        issues.append((first_movement_line, f"(Error) Missing required G-codes before first movement: {', '.join(missing_groups)}"))

    return issues

def check_end_gcode(lines_with_numbers):
    """
    Checks that M30 is the last G-code command.
    Allows blank lines or '%' symbols after M30.
    """
    found_m30 = False

    # Collect errors with line numbers
    errors = []

    for idx, (original_line_number, line) in enumerate(lines_with_numbers):
        if not line.strip() or line.strip() == "%":
            continue  # Skip empty lines or lines with only '%'

        if "M30" in line:
            if found_m30:
                errors.append((original_line_number, "(Error) M30 must be the last G-code command in the G-code."))
            found_m30 = True
            continue  # Continue to check if any G-code commands appear after M30

        # After M30, no other G-code commands should appear
        if found_m30 and gcode_pattern.search(line):
            errors.append((original_line_number, f"(Error) No G-code commands should appear after M30. Found '{line.strip()}'."))
    
    if not found_m30:
        if lines_with_numbers:
            last_line_number = lines_with_numbers[-1][0]
        else:
            last_line_number = 1
        errors.append((last_line_number, "(Error) M30 is missing from the G-code."))

    return errors

def check_spindle(lines_with_numbers):
    """
    Checks spindle-related issues in the G-code.
    """
    issues = []
    spindle_on = False
    spindle_started = False

    for idx, (original_line_number, line) in enumerate(lines_with_numbers):
        # Skip processing lines that are empty or contain only '%'
        if not line.strip() or line.strip() == "%":
            continue

        tokens = line.split()

        # Check for valid G-code commands
        if not gcode_pattern.search(line):
            issues.append((original_line_number, f"(Error) Invalid G-code command or syntax error -> {line.strip()}"))

        # Check for spindle on
        if "M03" in tokens or "M04" in tokens:
            # Check if spindle is already on
            if spindle_on:
                issues.append((original_line_number, "(Warning) Spindle is already on."))

            # Check if spindle speed is specified with 'S' command
            s_value_present = any(token.startswith("S") for token in tokens)
            if not s_value_present:
                issues.append((original_line_number, "(Error) Spindle speed (S value) is missing when turning on the spindle with M03/M04."))

            spindle_on = True
            spindle_started = True

        # Check for spindle off
        if "M05" in tokens:
            spindle_on = False

        # Check if movement commands are given without spindle on
        if any(cmd in tokens for cmd in interpolation_commands):
            if not spindle_on:
                issues.append((original_line_number, f"(Error) Move command without spindle on -> {line.strip()}"))

    # Check if spindle was turned off before M30
    if spindle_on:
        last_line_number = lines_with_numbers[-1][0]
        issues.append((last_line_number, "(Error) Spindle was not turned off (M05) before the end of the program."))

    # Check if spindle was never turned on
    if not spindle_started:
        issues.append((0, "(Error) Spindle was never turned on in the G-code."))

    return issues

def check_feed_rate(lines_with_numbers):
    """
    Checks feed rate related issues in the G-code.
    """
    issues = []
    last_feed_rate = None
    interpolation_command_seen = False

    for idx, (original_line_number, line) in enumerate(lines_with_numbers):
        # Skip processing lines that are empty or contain only '%'
        if not line.strip() or line.strip() == "%":
            continue

        tokens = line.split()
        commands = set(tokens)
        feed_rates = [token for token in tokens if token.startswith("F")]

        # Check if feed rate is beside non-interpolation commands
        if feed_rates and not any(cmd in interpolation_commands for cmd in commands):
            issues.append((original_line_number, f"(Warning) Feed rate specified without interpolation command -> {line.strip()}"))

        # Check for interpolation commands
        if any(cmd in commands for cmd in interpolation_commands):
            if not interpolation_command_seen:
                interpolation_command_seen = True
                if not feed_rates and last_feed_rate is None:
                    issues.append((original_line_number, f"(Error) First interpolation command must have a feed rate -> {line.strip()}"))
                else:
                    # Set initial feed rate
                    if feed_rates:
                        last_feed_rate = feed_rates[-1]
            else:
                # Check if feed rate is specified
                if feed_rates:
                    current_feed_rate = feed_rates[-1]
                    if current_feed_rate == last_feed_rate:
                        issues.append((original_line_number, f"(Warning) Feed rate {current_feed_rate} is already set; no need to specify again."))
                    else:
                        last_feed_rate = current_feed_rate

    return issues

def check_depth_of_cut(lines_with_numbers, depth_max=0.1):
    """
    Checks that all cutting moves on the Z-axis have a uniform depth and do not exceed the maximum depth.
    """
    getcontext().prec = 6  # Set precision as needed
    depth_max = Decimal(str(depth_max))
    issues = []

    positioning_mode = "G90"  # Default to absolute positioning
    current_z = Decimal('0.0')
    depths = set()
    z_negative_seen = False

    for idx, (original_line_number, line) in enumerate(lines_with_numbers):
        # Skip processing lines that are empty or contain only '%'
        if not line.strip() or line.strip() == "%":
            continue

        tokens = line.split()

        if "G90" in tokens:
            positioning_mode = "G90"
        elif "G91" in tokens:
            positioning_mode = "G91"

        if any(cmd in tokens for cmd in interpolation_commands.union(movement_commands)):
            z_values = [token for token in tokens if token.startswith("Z")]
            if z_values:
                try:
                    z_value = Decimal(z_values[-1][1:])
                except (ValueError, decimal.InvalidOperation):
                    issues.append((original_line_number, f"(Error) Invalid Z value -> {line.strip()}"))
                    continue

                if positioning_mode == "G90":
                    new_z = z_value
                elif positioning_mode == "G91":
                    new_z = current_z + z_value

                if new_z < Decimal('0.0'):
                    z_negative_seen = True
                    depth = abs(new_z)
                    depth = depth.quantize(Decimal('0.0001')).normalize()  # Round and remove trailing zeros
                    depths.add(depth)

                    if depth > depth_max:
                        issues.append((original_line_number, f"(Error) Depth of cut {depth} exceeds maximum allowed depth of {depth_max.normalize()} -> {line.strip()}"))

                current_z = new_z

    if z_negative_seen:
        if len(depths) > 1:
            depth_values = ', '.join(str(d.normalize()) for d in sorted(depths))
            issues.append((0, f"(Warning) Inconsistent depths of cut detected: {depth_values}"))
    else:
        issues.append((0, "(Error) No cutting moves detected on the Z-axis."))

    return issues

def check_interpolation_depth(lines_with_numbers):
    """
    Checks that all interpolation commands moving in X or Y are executed at a negative Z depth (i.e., cutting).
    Does not report errors for interpolation commands used for plunging or retracting (Z-axis movements only).
    """
    getcontext().prec = 6  # Set precision as needed
    issues = []

    positioning_mode = "G90"  # Default to absolute positioning
    current_z = Decimal('0.0')

    for idx, (original_line_number, line) in enumerate(lines_with_numbers):
        # Skip processing lines that are empty or contain only '%'
        if not line.strip() or line.strip() == "%":
            continue

        tokens = line.split()

        # Update positioning mode if G90 or G91 is found
        if "G90" in tokens:
            positioning_mode = "G90"
        elif "G91" in tokens:
            positioning_mode = "G91"

        # Check for Z-axis movement
        z_values = [token for token in tokens if token.startswith("Z")]
        if z_values:
            try:
                z_value = Decimal(z_values[-1][1:])
            except (ValueError, decimal.InvalidOperation):
                issues.append((original_line_number, f"(Error) Invalid Z value -> {line.strip()}"))
                continue

            # Calculate the new Z position based on positioning mode
            if positioning_mode == "G90":
                current_z = z_value
            elif positioning_mode == "G91":
                current_z += z_value

        # Check for interpolation commands
        if any(cmd in tokens for cmd in interpolation_commands):
            # Check if the command includes X or Y movement
            has_xy_movement = any(token.startswith(('X', 'Y')) for token in tokens)
            if has_xy_movement and current_z >= Decimal('0.0'):
                issues.append((original_line_number, f"(Warning) Interpolation command with XY movement executed without cutting depth (Z={current_z}) -> {line.strip()}"))

    return issues

def check_plunge_retract_moves(lines_with_numbers):
    """
    Checks that plunging and retracting moves along the Z-axis use G01 instead of G00.
    Reports an error if G00 is used for Z-axis movements to Z positions less than or equal to zero.
    """
    issues = []
    positioning_mode = "G90"  # Default to absolute positioning
    current_z = None  # Keep track of the current Z position

    for idx, (original_line_number, line) in enumerate(lines_with_numbers):
        # Skip processing lines that are empty or contain only '%'
        if not line.strip() or line.strip() == "%":
            continue

        tokens = line.split()

        # Update positioning mode if G90 or G91 is found
        if "G90" in tokens:
            positioning_mode = "G90"
        elif "G91" in tokens:
            positioning_mode = "G91"

        # Check for Z-axis movement
        z_values = [token for token in tokens if token.startswith("Z")]
        if z_values:
            try:
                z_value = Decimal(z_values[-1][1:])
            except (ValueError, decimal.InvalidOperation):
                issues.append((original_line_number, f"(Error) Invalid Z value -> {line.strip()}"))
                continue

            # Calculate the new Z position based on positioning mode
            if current_z is None:
                current_z = z_value
            else:
                if positioning_mode == "G90":
                    current_z = z_value
                elif positioning_mode == "G91":
                    current_z += z_value

            # Check for G00 commands moving to Z ≤ 0
            # Check for G00 commands moving to Z ≤ 0
            if "G00" in tokens and current_z <= Decimal('0.0'):
                issues.append((original_line_number, f"(Error) G00 used for plunging to Z={current_z}. Use G01 to safely approach the workpiece -> {line.strip()}"))

    return issues

def run_checks(gcode, depth_max=0.1):
    """
    Runs all checks and returns a tuple containing lists of errors and warnings.
    """
    errors = []
    warnings = []

    # Preprocess G-code to remove comments and get cleaned lines with original line numbers
    lines_with_numbers = preprocess_gcode(gcode)

    # Collect issues from all checks
    required_gcode_issues = check_required_gcodes(lines_with_numbers)
    required_gcode_position_issues = check_required_gcodes_position(lines_with_numbers)
    spindle_issues = check_spindle(lines_with_numbers)
    feed_rate_issues = check_feed_rate(lines_with_numbers)
    depth_issues = check_depth_of_cut(lines_with_numbers, depth_max)
    end_gcode_issues = check_end_gcode(lines_with_numbers)
    interpolation_depth_issues = check_interpolation_depth(lines_with_numbers)
    plunge_retract_issues = check_plunge_retract_moves(lines_with_numbers)

    # Combine all issues
    all_issues = (
        required_gcode_issues
        + required_gcode_position_issues
        + spindle_issues
        + feed_rate_issues
        + depth_issues
        + end_gcode_issues
        + interpolation_depth_issues
        + plunge_retract_issues
    )

    # Separate issues into errors and warnings
    for line_num, message in all_issues:
        if "(Error)" in message:
            errors.append((line_num, message))
        elif "(Warning)" in message:
            warnings.append((line_num, message))

    # Sort issues by line number
    errors.sort(key=lambda x: x[0])
    warnings.sort(key=lambda x: x[0])

    return errors, warnings

if __name__ == "__main__":
    # Example usage
    gcode_sample = """
    %
    G21 G90 G17 G54
    G00 X0 Y0 Z5.0
    M03 S1000
    G01 Z-0.1 F100  ; Plunge using rapid movement (should be G01)
    G54
    G01 Z-0.1
    G01 X10 Y10 
    G01 X20 Y20
    G00 Z5.0   ; Retract using rapid movement (allowed since Z > 0)
    M05
    M30
    %
    """

    depth_max = 0.1  # Set the maximum allowed depth of cut
    errors, warnings = run_checks(gcode_sample, depth_max)

    # Prepare the output as a string
    output_lines = []
    if errors or warnings:
        output_lines.append("Issues found in G-code:")
        for line_num, message in errors + warnings:
            if line_num > 0:
                output_lines.append(f"Line {line_num}: {message}")
            else:
                output_lines.append(message)
        print('\n'.join(output_lines))
    else:
        print("Your G-code looks good!")