fix(win): ensure openclaw CLI is on user PATH after install

electron-builder.yml

@@ -118,8 +118,6 @@ win:
 nsis:
   oneClick: false
   perMachine: false
-  # Avoid NSIS build failure: warning 6010 (_ci_StrContains "not referenced") is emitted when
-  # building the uninstaller, because that function is only used in the install macro.
   warningsAsErrors: false
   allowToChangeInstallationDirectory: true
   deleteAppDataOnUninstall: false

electron/utils/openclaw-cli.ts

@@ -104,6 +104,11 @@ function getPackagedCliWrapperPath(): string | null {
   return null;
 }
 
+function getWindowsPowerShellPath(): string {
+  const systemRoot = process.env.SystemRoot || 'C:\\Windows';
+  return join(systemRoot, 'System32', 'WindowsPowerShell', 'v1.0', 'powershell.exe');
+}
+
 // ── macOS / Linux install ────────────────────────────────────────────────────
 
 function getCliTargetPath(): string {
@@ -165,6 +170,71 @@ function isCliInstalled(): boolean {
   return true;
 }
 
+function ensureWindowsCliOnPath(): Promise<'updated' | 'already-present'> {
+  return new Promise((resolve, reject) => {
+    const cliWrapper = getPackagedCliWrapperPath();
+    if (!cliWrapper) {
+      reject(new Error('CLI wrapper not found in app resources.'));
+      return;
+    }
+
+    const cliDir = dirname(cliWrapper);
+    const helperPath = join(cliDir, 'update-user-path.ps1');
+    if (!existsSync(helperPath)) {
+      reject(new Error(`PATH helper not found at ${helperPath}`));
+      return;
+    }
+
+    const child = spawn(
+      getWindowsPowerShellPath(),
+      [
+        '-NoProfile',
+        '-NonInteractive',
+        '-ExecutionPolicy',
+        'Bypass',
+        '-File',
+        helperPath,
+        '-Action',
+        'add',
+        '-CliDir',
+        cliDir,
+      ],
+      {
+        env: process.env,
+        stdio: ['ignore', 'pipe', 'pipe'],
+        windowsHide: true,
+      },
+    );
+
+    let stdout = '';
+    let stderr = '';
+
+    child.stdout.on('data', (chunk) => {
+      stdout += chunk.toString();
+    });
+
+    child.stderr.on('data', (chunk) => {
+      stderr += chunk.toString();
+    });
+
+    child.on('error', reject);
+    child.on('close', (code) => {
+      if (code !== 0) {
+        reject(new Error(stderr.trim() || `PowerShell exited with code ${code}`));
+        return;
+      }
+
+      const status = stdout.trim();
+      if (status === 'updated' || status === 'already-present') {
+        resolve(status);
+        return;
+      }
+
+      reject(new Error(`Unexpected PowerShell output: ${status || '(empty)'}`));
+    });
+  });
+}
+
 function ensureLocalBinInPath(): void {
   if (process.platform === 'win32') return;
 
@@ -205,7 +275,17 @@ export async function autoInstallCliIfNeeded(
   notify?: (path: string) => void,
 ): Promise<void> {
   if (!app.isPackaged) return;
-  if (process.platform === 'win32') return; // NSIS handles it
+  if (process.platform === 'win32') {
+    try {
+      const result = await ensureWindowsCliOnPath();
+      if (result === 'updated') {
+        logger.info('Added Windows CLI directory to user PATH.');
+      }
+    } catch (error) {
+      logger.warn('Failed to ensure Windows CLI is on PATH:', error);
+    }
+    return;
+  }
 
   const target = getCliTargetPath();
   const wrapperSrc = getPackagedCliWrapperPath();

resources/cli/win32/update-user-path.ps1

@@ -0,0 +1,88 @@
+param(
+  [Parameter(Mandatory = $true)]
+  [ValidateSet('add', 'remove')]
+  [string]$Action,
+
+  [Parameter(Mandatory = $true)]
+  [string]$CliDir
+)
+
+$ErrorActionPreference = 'Stop'
+
+function Normalize-PathEntry {
+  param([string]$Value)
+
+  if ([string]::IsNullOrWhiteSpace($Value)) {
+    return ''
+  }
+
+  return $Value.Trim().Trim('"').TrimEnd('\').ToLowerInvariant()
+}
+
+$current = [Environment]::GetEnvironmentVariable('Path', 'User')
+$entries = @()
+if (-not [string]::IsNullOrWhiteSpace($current)) {
+  $entries = $current -split ';' | Where-Object { -not [string]::IsNullOrWhiteSpace($_) }
+}
+
+$target = Normalize-PathEntry $CliDir
+$seen = [System.Collections.Generic.HashSet[string]]::new()
+$nextEntries = New-Object System.Collections.Generic.List[string]
+
+foreach ($entry in $entries) {
+  $normalized = Normalize-PathEntry $entry
+  if ([string]::IsNullOrWhiteSpace($normalized)) {
+    continue
+  }
+
+  if ($normalized -eq $target) {
+    continue
+  }
+
+  if ($seen.Add($normalized)) {
+    $nextEntries.Add($entry.Trim().Trim('"'))
+  }
+}
+
+$status = 'already-present'
+if ($Action -eq 'add') {
+  if ($seen.Add($target)) {
+    $nextEntries.Add($CliDir)
+    $status = 'updated'
+  }
+} elseif ($entries.Count -ne $nextEntries.Count) {
+  $status = 'updated'
+}
+
+$newPath = if ($nextEntries.Count -eq 0) { $null } else { $nextEntries -join ';' }
+[Environment]::SetEnvironmentVariable('Path', $newPath, 'User')
+
+Add-Type -Namespace OpenClaw -Name NativeMethods -MemberDefinition @"
+using System;
+using System.Runtime.InteropServices;
+public static class NativeMethods {
+  [DllImport("user32.dll", SetLastError = true, CharSet = CharSet.Auto)]
+  public static extern IntPtr SendMessageTimeout(
+    IntPtr hWnd,
+    int Msg,
+    IntPtr wParam,
+    string lParam,
+    int fuFlags,
+    int uTimeout,
+    out IntPtr lpdwResult
+  );
+}
+"@
+
+$result = [IntPtr]::Zero
+[OpenClaw.NativeMethods]::SendMessageTimeout(
+  [IntPtr]0xffff,
+  0x001A,
+  [IntPtr]::Zero,
+  'Environment',
+  0x0002,
+  5000,
+  [ref]$result
+) | Out-Null
+
+Write-Output $status

scripts/bundle-openclaw.mjs

@@ -479,6 +479,31 @@ function findFirstFileByName(rootDir, matcher) {
   return null;
 }
 
+function findFilesByName(rootDir, matcher) {
+  const matches = [];
+  const stack = [rootDir];
+  while (stack.length > 0) {
+    const current = stack.pop();
+    let entries = [];
+    try {
+      entries = fs.readdirSync(current, { withFileTypes: true });
+    } catch {
+      continue;
+    }
+    for (const entry of entries) {
+      const fullPath = path.join(current, entry.name);
+      if (entry.isDirectory()) {
+        stack.push(fullPath);
+        continue;
+      }
+      if (entry.isFile() && matcher.test(entry.name)) {
+        matches.push(fullPath);
+      }
+    }
+  }
+  return matches;
+}
+
 function patchBundledRuntime(outputDir) {
   const replacePatches = [
     {
@@ -602,6 +627,63 @@ function patchBundledRuntime(outputDir) {
   if (count > 0) {
     echo`   🩹 Patched ${count} bundled runtime spawn site(s)`;
   }
+
+  const ptyTargets = findFilesByName(
+    path.join(outputDir, 'dist'),
+    /^(subagent-registry|reply|pi-embedded)-.*\.js$/,
+  );
+  const ptyPatches = [
+    {
+      label: 'pty launcher windowsHide',
+      search: `\tconst pty = spawn(params.shell, params.args, {
+\t\tcwd: params.cwd,
+\t\tenv: params.env ? toStringEnv(params.env) : void 0,
+\t\tname: params.name ?? process.env.TERM ?? "xterm-256color",
+\t\tcols: params.cols ?? 120,
+\t\trows: params.rows ?? 30
+\t});`,
+      replace: `\tconst pty = spawn(params.shell, params.args, {
+\t\tcwd: params.cwd,
+\t\tenv: params.env ? toStringEnv(params.env) : void 0,
+\t\tname: params.name ?? process.env.TERM ?? "xterm-256color",
+\t\tcols: params.cols ?? 120,
+\t\trows: params.rows ?? 30,
+\t\twindowsHide: true
+\t});`,
+    },
+    {
+      label: 'disable pty on windows',
+      search: `\t\t\tconst usePty = params.pty === true && !sandbox;`,
+      replace: `\t\t\tconst usePty = params.pty === true && !sandbox && process.platform !== "win32";`,
+    },
+    {
+      label: 'disable approval pty on windows',
+      search: `\t\t\t\t\tpty: params.pty === true && !sandbox,`,
+      replace: `\t\t\t\t\tpty: params.pty === true && !sandbox && process.platform !== "win32",`,
+    },
+  ];
+
+  let ptyCount = 0;
+  for (const patch of ptyPatches) {
+    let matchedAny = false;
+    for (const target of ptyTargets) {
+      const current = fs.readFileSync(target, 'utf8');
+      if (!current.includes(patch.search)) continue;
+      matchedAny = true;
+      const next = current.replaceAll(patch.search, patch.replace);
+      if (next !== current) {
+        fs.writeFileSync(target, next, 'utf8');
+        ptyCount++;
+      }
+    }
+    if (!matchedAny) {
+      echo`   ⚠️  Skipped patch for ${patch.label}: expected source snippet not found`;
+    }
+  }
+
+  if (ptyCount > 0) {
+    echo`   🩹 Patched ${ptyCount} bundled PTY site(s)`;
+  }
 }
 
 patchBrokenModules(outputNodeModules);

scripts/installer.nsh

@@ -79,107 +79,32 @@
   ; elevation this call silently fails — no crash, just no key written.
   WriteRegDWORD HKLM "SYSTEM\CurrentControlSet\Control\FileSystem" "LongPathsEnabled" 1
 
-  ; Add resources\cli to the current user's PATH for openclaw CLI.
+  ; Use PowerShell to update the current user's PATH.
-  ; Read current PATH, skip if already present, append otherwise.
+  ; This avoids NSIS string-buffer limits and preserves long PATH values.
-  ;
+  InitPluginsDir
-  ; ReadRegStr silently returns "" when the value exceeds the NSIS string
-  ; buffer (8192 chars for the electron-builder large-strings build).
-  ; Without an error-flag check we would overwrite the entire user PATH with
-  ; only our CLI directory, destroying every other PATH entry.
   ClearErrors
-  ReadRegStr $0 HKCU "Environment" "Path"
+  File "/oname=$PLUGINSDIR\update-user-path.ps1" "..\resources\cli\win32\update-user-path.ps1"
-  IfErrors _ci_readFailed
+  ExecWait '"$SYSDIR\WindowsPowerShell\v1.0\powershell.exe" -NoProfile -NonInteractive -ExecutionPolicy Bypass -File "$PLUGINSDIR\update-user-path.ps1" -Action add -CliDir "$INSTDIR\resources\cli"' $0
-
+  IfErrors 0 +2
-  StrCmp $0 "" _ci_setNew
+    DetailPrint "Warning: Failed to launch PowerShell while updating PATH."
-
+  StrCmp $0 "0" 0 +2
-  ; Check if our CLI dir is already in PATH
-  Push "$INSTDIR\resources\cli"
-  Push $0
-  Call _ci_StrContains
-  Pop $1
-  StrCmp $1 "" 0 _ci_done
-
-  ; Append to existing PATH
-  StrCpy $0 "$0;$INSTDIR\resources\cli"
-  Goto _ci_write
-
-  _ci_setNew:
-    StrCpy $0 "$INSTDIR\resources\cli"
-
-  _ci_write:
-    WriteRegExpandStr HKCU "Environment" "Path" $0
-    ; Broadcast WM_SETTINGCHANGE so running Explorer/terminals pick up the change
-    SendMessage ${HWND_BROADCAST} ${WM_SETTINGCHANGE} 0 "STR:Environment" /TIMEOUT=500
     Goto _ci_done
-
+  DetailPrint "Warning: PowerShell PATH update exited with code $0."
-  _ci_readFailed:
-    ; PATH value could not be read (likely exceeds NSIS buffer).
-    ; Skip modification to avoid destroying existing entries.
-    DetailPrint "Warning: Could not read user PATH (may exceed 8192 chars). Skipping PATH update."
 
   _ci_done:
 !macroend
 
-; Helper: check if $R0 (needle) is found within $R1 (haystack).
-; Pushes needle then haystack before call; pops result (needle if found, "" if not).
-Function _ci_StrContains
-  Exch $R1 ; haystack
-  Exch
-  Exch $R0 ; needle
-  Push $R2
-  Push $R3
-  Push $R4
-
-  StrLen $R3 $R0
-  StrLen $R4 $R1
-  IntOp $R4 $R4 - $R3
-
-  StrCpy $R2 0
-  _ci_loop:
-    IntCmp $R2 $R4 0 0 _ci_notfound
-    StrCpy $1 $R1 $R3 $R2
-    StrCmp $1 $R0 _ci_found
-    IntOp $R2 $R2 + 1
-    Goto _ci_loop
-
-  _ci_found:
-    StrCpy $R0 $R0
-    Goto _ci_end
-
-  _ci_notfound:
-    StrCpy $R0 ""
-
-  _ci_end:
-    Pop $R4
-    Pop $R3
-    Pop $R2
-    Pop $R1
-    Exch $R0
-FunctionEnd
-
 !macro customUnInstall
-  ; Remove resources\cli from user PATH
+  ; Remove resources\cli from user PATH via PowerShell so long PATH values are handled safely
+  InitPluginsDir
   ClearErrors
-  ReadRegStr $0 HKCU "Environment" "Path"
+  File "/oname=$PLUGINSDIR\update-user-path.ps1" "..\resources\cli\win32\update-user-path.ps1"
-  IfErrors _cu_pathDone
+  ExecWait '"$SYSDIR\WindowsPowerShell\v1.0\powershell.exe" -NoProfile -NonInteractive -ExecutionPolicy Bypass -File "$PLUGINSDIR\update-user-path.ps1" -Action remove -CliDir "$INSTDIR\resources\cli"' $0
-  StrCmp $0 "" _cu_pathDone
+  IfErrors 0 +2
-
+    DetailPrint "Warning: Failed to launch PowerShell while removing PATH entry."
-  ; Remove our entry (with leading or trailing semicolons)
+  StrCmp $0 "0" 0 +2
-  Push $0
+    Goto _cu_pathDone
-  Push "$INSTDIR\resources\cli"
+  DetailPrint "Warning: PowerShell PATH removal exited with code $0."
-  Call un._cu_RemoveFromPath
-  Pop $0
-
-  ; If PATH is now empty, delete the registry value instead of writing ""
-  StrCmp $0 "" _cu_deletePath
-  WriteRegExpandStr HKCU "Environment" "Path" $0
-  Goto _cu_pathBroadcast
-
-  _cu_deletePath:
-    DeleteRegValue HKCU "Environment" "Path"
-
-  _cu_pathBroadcast:
-    SendMessage ${HWND_BROADCAST} ${WM_SETTINGCHANGE} 0 "STR:Environment" /TIMEOUT=500
 
   _cu_pathDone:
 
@@ -219,70 +144,3 @@ FunctionEnd
   _cu_skipRemove:
 !macroend
 
-; Uninstaller helper: remove a substring from a semicolon-delimited PATH string.
-; Push haystack, push needle before call; pops cleaned string.
-Function un._cu_RemoveFromPath
-  Exch $R0 ; needle
-  Exch
-  Exch $R1 ; haystack
-
-  ; Try removing ";needle" (entry in the middle or end)
-  Push "$R1"
-  Push ";$R0"
-  Call un._ci_StrReplace
-  Pop $R1
-
-  ; Try removing "needle;" (entry at the start)
-  Push "$R1"
-  Push "$R0;"
-  Call un._ci_StrReplace
-  Pop $R1
-
-  ; Try removing exact match (only entry)
-  StrCmp $R1 $R0 0 +2
-    StrCpy $R1 ""
-
-  Pop $R0
-  Exch $R1
-FunctionEnd
-
-; Uninstaller helper: remove first occurrence of needle from haystack.
-; Push haystack, push needle; pops result.
-Function un._ci_StrReplace
-  Exch $R0 ; needle
-  Exch
-  Exch $R1 ; haystack
-  Push $R2
-  Push $R3
-  Push $R4
-  Push $R5
-
-  StrLen $R3 $R0
-  StrLen $R4 $R1
-  StrCpy $R5 ""
-  StrCpy $R2 0
-
-  _usr_loop:
-    IntCmp $R2 $R4 _usr_done _usr_done
-    StrCpy $1 $R1 $R3 $R2
-    StrCmp $1 $R0 _usr_found
-    StrCpy $1 $R1 1 $R2
-    StrCpy $R5 "$R5$1"
-    IntOp $R2 $R2 + 1
-    Goto _usr_loop
-
-  _usr_found:
-    ; Copy the part after the needle
-    IntOp $R2 $R2 + $R3
-    StrCpy $1 $R1 "" $R2
-    StrCpy $R5 "$R5$1"
-
-  _usr_done:
-    StrCpy $R1 $R5
-    Pop $R5
-    Pop $R4
-    Pop $R3
-    Pop $R2
-    Pop $R0
-    Exch $R1
-FunctionEnd