Standard-Machine: UDC data backup + restore scripts for PC swap workflow
Backup-UDCData.bat / Backup-UDCData.ps1: tech-runnable, UAC-self-elevating. Run on the OLD PC before retirement; reads bay number from udc_settings.json, copies CurrentData.json + ArchiveData/ to \\tsgwp00525\...\backup\udc\<bay>\, drops backup.manifest.json. Refuses the 9999 placeholder so backups never collide across PCs. Restore-UDCData.ps1: idempotent, designed for the manifest engine. 99% of cycles silent no-op (sub-second, zero side effects); 1% (cycle after a backup lands at this PC's bay) restores files locally, moves consumed backup to <bay>\migrated\<timestamp>\, writes restore.manifest.json, relaunches UDC. Round-trip + no-op fast path verified end-to-end on the win11 analyzer VM. Already wired into the Standard-Machine GE-Enforce manifest at standard-machine\manifest.json on the v2 share. Complementary to the placeholder-to-real branch in Update-MachineNumber.ps1: that branch covers the 9999 -> real flow, this one covers the pre-imaged-then-swapped flow where Update-MachineNumber already ran before any backup existed. Both safely no-op if the other consumed. Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
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cproudlock
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playbook/shopfloor-setup/Standard/Restore-UDCData.ps1
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playbook/shopfloor-setup/Standard/Restore-UDCData.ps1
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# Restore-UDCData.ps1 - Idempotent UDC data restore for the manifest engine.
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#
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# Triggered by the GE Shopfloor Enforce scheduled task (runs as SYSTEM, every
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# user logon + every 5 min). Standard-machine manifest entry uses
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# DetectionMethod=Always so this fires every cycle; the script self-decides
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# whether there's actually any work to do.
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#
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# CONTRACT:
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# - 99% of cycles: no backup waiting -> exit 0 in ~1 second, no side effects
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# - 1 cycle (the one after Backup-UDCData lands a backup for this PC's bay):
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# stop UDC, copy CurrentData.json + ArchiveData/ to C:\ProgramData\UDC,
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# move consumed backup to <bay>\migrated\<timestamp>\, write
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# restore.manifest.json, restart UDC. After this, root is empty so the
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# check returns "no backup waiting" again on subsequent cycles.
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#
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# DESIGNED FOR THE SWAP WORKFLOW:
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# New PC gets pre-imaged with real machine number + locked down, sits in
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# storage. Days/weeks later, tech runs Backup-UDCData on old PC -> backup
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# lands on share. Tech swaps PCs. New PC powers on at the bay -> ShopFloor
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# autologon -> manifest engine fires this script -> backup detected ->
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# restored -> UDC opens with prior history intact.
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#
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# Replaces the placeholder->real trigger in Update-MachineNumber.ps1 for the
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# pre-imaged-then-swapped case (where the trigger fired at imaging time, before
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# the backup existed). Update-MachineNumber.ps1's branch still handles the
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# secondary case (tech used 9999 placeholder + sets number at bay) - both
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# triggers safely no-op if the other already consumed the backup.
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[CmdletBinding()]
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param(
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[string]$BackupShareRoot = '\\tsgwp00525.wjs.geaerospace.net\shared\dt\shopfloor\backup\udc',
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[string]$UdcDataDir = 'C:\ProgramData\UDC',
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[string]$UdcExePath = 'C:\Program Files\UDC\UDC.exe',
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[string]$UdcSettingsPath = 'C:\ProgramData\UDC\udc_settings.json',
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[string]$Site = 'West Jefferson'
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)
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$ErrorActionPreference = 'Stop'
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$logDir = 'C:\Logs\UDC'
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if (-not (Test-Path $logDir)) {
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try { New-Item -Path $logDir -ItemType Directory -Force | Out-Null } catch { $logDir = $env:TEMP }
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}
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$logFile = Join-Path $logDir 'Restore-UDCData.log'
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function Log {
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param([string]$Msg, [string]$Level = 'INFO')
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$ts = Get-Date -Format 'yyyy-MM-dd HH:mm:ss'
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$line = "[$ts][$Level] $Msg"
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Add-Content -LiteralPath $logFile -Value $line
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Write-Host $line
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}
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# --- Resolve local machine number ---
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if (-not (Test-Path -LiteralPath $UdcSettingsPath)) {
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# No UDC installed yet. Manifest engine will catch up later if/when it lands.
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exit 0
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}
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try {
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$json = Get-Content -LiteralPath $UdcSettingsPath -Raw | ConvertFrom-Json
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$mn = $json.GeneralSettings.MachineNumber
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} catch {
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Log "Failed to parse $UdcSettingsPath : $_" 'ERROR'
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exit 0
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}
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if (-not $mn -or $mn -eq '9999' -or $mn -notmatch '^\d+$') {
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# Placeholder or invalid - the placeholder->real trigger in
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# Update-MachineNumber.ps1 will catch it when the tech sets a real number.
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exit 0
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}
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# --- Probe for a waiting backup ---
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$bayDir = Join-Path $BackupShareRoot $mn
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$srcCur = Join-Path $bayDir 'CurrentData.json'
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$srcArc = Join-Path $bayDir 'ArchiveData'
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if (-not (Test-Path -LiteralPath $srcCur)) {
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# Most-common path: no backup waiting. Exit silently to keep enforce-cycle
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# logs clean. (Manifest engine still records that the entry ran.)
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exit 0
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}
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# We have a backup. From here on, log everything.
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Log "==============================================="
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Log "UDC data backup detected at $bayDir - restoring."
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Log "Hostname: $env:COMPUTERNAME"
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Log "Machine number: $mn"
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# --- Stop UDC.exe so CurrentData.json isn't locked ---
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Get-Process UDC -ErrorAction SilentlyContinue | ForEach-Object {
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try {
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$_.Kill()
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$_.WaitForExit(5000) | Out-Null
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Log "Stopped existing UDC.exe (PID $($_.Id))"
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} catch {
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Log "Could not stop UDC.exe (PID $($_.Id)): $_" 'WARN'
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}
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}
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Start-Sleep -Milliseconds 500
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# --- Ensure local UDC data dir exists ---
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if (-not (Test-Path -LiteralPath $UdcDataDir)) {
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New-Item -ItemType Directory -Path $UdcDataDir -Force | Out-Null
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}
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$localCur = Join-Path $UdcDataDir 'CurrentData.json'
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$localArc = Join-Path $UdcDataDir 'ArchiveData'
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# --- Copy CurrentData.json ---
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$copiedCur = $false
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try {
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Copy-Item -LiteralPath $srcCur -Destination $localCur -Force -ErrorAction Stop
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$copiedCur = $true
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Log "Copied CurrentData.json ($((Get-Item $localCur).Length) bytes)"
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} catch {
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Log "Copy CurrentData.json failed: $_" 'ERROR'
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}
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# --- Copy ArchiveData/ ---
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$copiedArc = $false
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$arcFiles = 0
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$arcBytes = 0
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if (Test-Path -LiteralPath $srcArc) {
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try {
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if (Test-Path -LiteralPath $localArc) {
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Remove-Item -LiteralPath $localArc -Recurse -Force -ErrorAction SilentlyContinue
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}
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Copy-Item -LiteralPath $srcArc -Destination $localArc -Recurse -Force -ErrorAction Stop
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$arcItems = Get-ChildItem -LiteralPath $localArc -Recurse -File -ErrorAction SilentlyContinue
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$arcFiles = $arcItems.Count
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$arcBytes = ($arcItems | Measure-Object Length -Sum).Sum
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$copiedArc = $true
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Log "Copied ArchiveData/ ($arcFiles files, $arcBytes bytes)"
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} catch {
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Log "Copy ArchiveData/ failed: $_" 'ERROR'
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}
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}
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# --- One-shot consumption: only move backup -> migrated/ if BOTH copies succeeded ---
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# (If one failed, leave the live backup in place so the next cycle can retry.)
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$consumeOk = ($copiedCur -and ($copiedArc -or -not (Test-Path -LiteralPath $srcArc)))
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if ($consumeOk) {
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try {
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$stamp = Get-Date -Format 'yyyy-MM-ddTHH-mm-ssZ'
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$migDir = Join-Path $bayDir 'migrated'
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$migStamp = Join-Path $migDir $stamp
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if (-not (Test-Path -LiteralPath $migDir)) { New-Item -ItemType Directory -Path $migDir -Force | Out-Null }
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if (-not (Test-Path -LiteralPath $migStamp)) { New-Item -ItemType Directory -Path $migStamp -Force | Out-Null }
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Move-Item -LiteralPath $srcCur -Destination (Join-Path $migStamp 'CurrentData.json') -Force -ErrorAction Stop
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if (Test-Path -LiteralPath $srcArc) {
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Move-Item -LiteralPath $srcArc -Destination (Join-Path $migStamp 'ArchiveData') -Force -ErrorAction Stop
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}
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$bakManifest = Join-Path $bayDir 'backup.manifest.json'
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if (Test-Path -LiteralPath $bakManifest) {
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Move-Item -LiteralPath $bakManifest -Destination (Join-Path $migStamp 'backup.manifest.json') -Force -ErrorAction SilentlyContinue
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}
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$restoreManifest = [ordered]@{
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RestoredAt = (Get-Date -Format 'o')
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DestinationHostname = $env:COMPUTERNAME
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DestinationUser = [System.Security.Principal.WindowsIdentity]::GetCurrent().Name
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MachineNumber = $mn
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CurrentDataBytes = (Get-Item $localCur).Length
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ArchiveDataFiles = $arcFiles
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ArchiveDataBytes = $arcBytes
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RestoredVia = 'Restore-UDCData.ps1 (manifest engine, on logon)'
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}
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$restoreManifest | ConvertTo-Json | Set-Content -Path (Join-Path $migStamp 'restore.manifest.json') -Encoding UTF8
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Log "Backup consumed -> migrated\$stamp\"
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} catch {
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Log "Move-to-migrated failed (data IS restored locally, but live backup remains - next cycle will retry consumption): $_" 'ERROR'
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}
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} else {
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Log "Restore incomplete - leaving live backup at $bayDir for retry next cycle." 'WARN'
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}
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# --- Relaunch UDC with the current machine number args so it picks up the
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# restored CurrentData.json. UDC's vendor autostart in HKLM\Run will also
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# fire on the next user logon, so this is belt-and-suspenders for the
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# same-session case (e.g. tech is at the keyboard during the restore). ---
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if ((Test-Path -LiteralPath $UdcExePath) -and $copiedCur) {
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try {
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Start-Process -FilePath $UdcExePath -ArgumentList @("`"$Site`"", "-$mn")
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Log "Relaunched UDC.exe with `"$Site`" -$mn"
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} catch {
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Log "UDC relaunch failed: $_" 'WARN'
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}
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}
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Log "==============================================="
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exit 0
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