Root cause: portable zip was 1MB skeleton; first launch triggered
`npm install` of OpenClaw + 36 bundled deps on customer's USB drive.
On exFAT-formatted USB this hangs/takes 20+ minutes, gateway never
binds 18789, dashboard shows "Gateway 未启动".
Fix follows StanleyChanH/openclaw-offline-package pattern (153MB
single-platform zip, gateway starts directly):
- release.yml: only build Windows bundle (~150-200MB). Mac users
fall back to setup.sh. Reasoning: 99% of customers are Windows;
bundling 3 platforms × Node ~30MB + 3× node_modules dedup pain
is what blew the previous attempt past GitHub's 2GB cap (see
5916ff5 history). Smaller scope = simpler + safer.
- Windows-Start.bat / Mac-Start.command: warn if node_modules
missing; fallback `npm install` adds --ignore-scripts --no-audit
--no-fund for speed.
- Release notes: NTFS U-disk recommendation.
Lessons applied (from 5916ff5):
- Stay on linux runner with --ignore-scripts (Stanley pattern)
- Drop mac-x64 / mac-arm64 Node from bundle (setup.sh handles Mac)
- rm -rf node-llama-cpp / sharp / canvas explicitly
- Hard size guard: fail CI if zip > 1500MB (buffer below 2GB cap)
Two real bugs in the portable launchers:
1. Windows-Install.bat: xcopy reads from %TEMP%\node-<ver>-win-x64
but Expand-Archive extracts into %TEMP%\node-extract\node-<ver>-win-x64.
Result: empty runtime\node-win-x64\ on networked install path.
2. Mac-Start.command + Windows-Start.bat: legacy-config sync block
was placed AFTER the default-config block, so the "config.json
exists but openclaw.json doesn't" branch was unreachable. Existing
USB users with config.json never got their settings migrated;
they got the empty default instead.
Reordered so legacy migration runs first, default only as fallback.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
- Delete usb-scripts/, Linux-*.sh, setup-linux-usb.sh, migrate.js
- Rename core-mac/core-win → core (with migration shims for existing USBs)
- Fix Mac-Menu.command ARM64 hardcode — now detects Intel/Apple Silicon
- setup.sh: remove Linux branch, Windows download only with --all-platforms
- Update README.md and CLAUDE.md to reflect Mac + Windows only
Major fixes for Windows portable version:
1. **Fixed critical bugs:**
- Replace Unix /dev/null with Windows nul in all .bat files
- Unified config path to data/.openclaw/openclaw.json
- Fixed cross-platform node_modules compatibility issue
2. **Implemented separated core directories:**
- app/core-mac/ for Mac dependencies
- app/core-win/ for Windows dependencies
- Prevents cross-platform file system conflicts
- Shared data/ directory for configs and memory
3. **Enhanced setup.sh:**
- Now downloads both Mac and Windows Node.js runtimes
- Ensures U-Claw works on both platforms after setup
4. **Added diagnostic tools:**
- Windows-Diagnose.bat for troubleshooting
- Mac-Diagnose.command for troubleshooting
- Auto-generates diagnostic-log.txt
5. **Improved user experience:**
- Added Welcome.html - Simple 3-step guide in Chinese
- All scripts updated to use platform-specific core directories
- Better error messages and user guidance
Files modified:
- portable/Windows-Start.bat: Use core-win, fix syntax
- portable/Windows-Menu.bat: Use core-win, fix syntax
- portable/Mac-Start.command: Use core-mac
- portable/Mac-Menu.command: Use core-mac
- portable/setup.sh: Download both platforms, use core-mac
Files added:
- portable/Windows-Diagnose.bat: Diagnostic tool
- portable/Mac-Diagnose.command: Diagnostic tool
- portable/Welcome.html: User-friendly welcome page
🤖 Generated with [Claude Code](https://claude.com/claude-code)
Co-Authored-By: Claude <noreply@anthropic.com>
- openclaw.mjs is at node_modules/openclaw/openclaw.mjs, not core root
- Remove npm run build (openclaw doesn't need a build step via npm)
- Fix both Mac-Start.command and Mac-Menu.command
- Add U-Claw.html navigation page with OS auto-detection and live status
- Rename scripts: start → Mac-Start/Windows-Start, menu → Mac-Menu/Windows-Menu
- Update installer scripts to reference new v2 directory structure (app/core)
- Update .gitignore to exclude build artifacts and marketing assets
