pxe-server/playbook/shopfloor-setup/gea-shopfloor-waxtrace/09-Setup-WaxAndTrace.ps1

# 09-Setup-WaxAndTrace.ps1 - Wax and Trace pc-type setup (Mitutoyo FormTracePak v6.0)
#
# Imaging-time install. Mitutoyo's CD-ROM-bound VB6 wrapper (Setup.exe +
# appSetup.exe) is unreliable on Win11 and requires interactive clicks
# through model + cal + HASP dialogs. We bypass it entirely: prereqs install
# via manifest, FormTracePak itself is xcopy + reg-import from a master capture.
#
# Master capture was taken 2026-05-18 on a Win11 VM with both CV-3000/4000
# series + SV-C3000/4000 series installed via Mount-DiskImage approach (see
# project-waxtrace-image.md). Covers all WJ wax/trace bays since both series
# end up sharing the same Program Files dir + reg.
#
# Layout at C:\WaxTrace-Install\ (xcopied by startnet.cmd):
#   waxtrace-manifest.json
#   09-Setup-WaxAndTrace.ps1   (this file)
#   prereqs\vcredist_x86.exe   (VC++ 2008 x86)
#   prereqs\vcredist_x64.exe   (VC++ 2008 x64)
#   prereqs\vc_redist.x86.exe  (VC++ 2017 x86)
#   prereqs\vc_redist.x64.exe  (VC++ 2017 x64)
#   prereqs\HASPUserSetup.exe  (Sentinel Runtime / HASP dongle driver)
#   captured\pf-x86-MitutoyoApp.zip      (~108 MB compressed -> 675 MB)
#   captured\c-MitutoyoApp.zip           (data dir skeleton, mostly empty)
#   captured\reg\hklm-wow-mitutoyo.reg.gz (gzipped, ~218 KB -> 5.4 MB)
#   captured\arp-entries.json            (informational - what to expect)
#   calibrations\CAL-WJRP<asset>_serial-<sn>_probe-<probe>.iso (per-machine)
#
# Per-machine calibration is applied separately (mount cal ISO + run its
# Setup.exe), keyed by C:\Enrollment\machine-number.txt.
#
# Log: C:\Logs\WaxTrace\09-Setup-WaxAndTrace.log
#      C:\Logs\WaxTrace\install.log (written by Install-FromManifest)

$ErrorActionPreference = 'Continue'

# Mirror the CMM pattern (09-Setup-CMM.ps1): the script itself lives in the
# shopfloor-setup tree (xcopied during WinPE), but the bulky bootstrap bundle
# (prereqs + captured master + cal ISOs) lives at C:\WaxTrace-Install\, put
# there by startnet.cmd from Y:\installers-post\waxtrace\ at imaging time.
$stagingRoot   = 'C:\WaxTrace-Install'
$manifestPath  = Join-Path $stagingRoot 'waxtrace-manifest.json'
$libSource     = Join-Path $PSScriptRoot '..\common\lib\Install-FromManifest.ps1'

$logDir        = 'C:\Logs\WaxTrace'
$installLog    = Join-Path $logDir 'install.log'
$transcriptLog = Join-Path $logDir '09-Setup-WaxAndTrace.log'

if (-not (Test-Path $logDir)) {
    New-Item -Path $logDir -ItemType Directory -Force | Out-Null
}

try { Start-Transcript -Path $transcriptLog -Append -Force | Out-Null } catch {}

function Write-WTLog {
    param([string]$Message, [string]$Level = 'INFO')
    $stamp = Get-Date -Format "yyyy-MM-dd HH:mm:ss"
    Write-Host "[$stamp] [$Level] $Message"
}

Write-WTLog "================================================================"
Write-WTLog "=== WaxTrace Setup (imaging-time) session start (PID $PID) ==="
Write-WTLog "Running as: $([System.Security.Principal.WindowsIdentity]::GetCurrent().Name)"
Write-WTLog "Script root: $PSScriptRoot"
Write-WTLog "================================================================"

# Status push - best-effort.
$pxeStatusLib = Join-Path $PSScriptRoot '..\Shopfloor\lib\Send-PxeStatus.ps1'
if (Test-Path $pxeStatusLib) {
    try { . $pxeStatusLib; Send-PxeStatus -Stage '09-Setup-WaxAndTrace: starting' -StageIndex 3 -StageTotal 8 } catch { }
}

foreach ($file in @('pc-type.txt','machine-number.txt')) {
    $path = "C:\Enrollment\$file"
    if (Test-Path -LiteralPath $path) {
        $content = (Get-Content -LiteralPath $path -First 1 -ErrorAction SilentlyContinue).Trim()
        Write-WTLog "  $file = $content"
    } else {
        Write-WTLog "  $file = (not present)"
    }
}

# ============================================================================
# Step 1: Prereqs via manifest (VC++ 2008 + 2017, HASP/Sentinel)
# ============================================================================
if (-not (Test-Path $manifestPath)) {
    Write-WTLog "waxtrace-manifest.json not found at $manifestPath" 'ERROR'
} elseif (-not (Test-Path $libSource)) {
    Write-WTLog "Install-FromManifest.ps1 not found at $libSource" 'ERROR'
} else {
    Write-WTLog "Running Install-FromManifest (InstallerRoot=$PSScriptRoot)"
    & $libSource -ManifestPath $manifestPath -InstallerRoot $stagingRoot -LogFile $installLog
    $rc = $LASTEXITCODE
    Write-WTLog "Install-FromManifest returned $rc"
}

# ============================================================================
# Step 2: Replay FormTracePak install from master capture
# ============================================================================
# Detection: skip if Formtracepak already present (re-run safe).
$ftpakExe = 'C:\Program Files (x86)\MitutoyoApp\Formtracepak\Formtracepak.exe'
if (Test-Path -LiteralPath $ftpakExe) {
    Write-WTLog "Formtracepak.exe already present - skipping replay"
} else {
    $pfZip = Join-Path $stagingRoot 'captured\pf-x86-MitutoyoApp.zip'
    $maZip = Join-Path $stagingRoot 'captured\c-MitutoyoApp.zip'
    $regGz = Join-Path $stagingRoot 'captured\reg\hklm-wow-mitutoyo.reg.gz'

    if (-not (Test-Path $pfZip)) {
        Write-WTLog "Master capture pf-x86-MitutoyoApp.zip not found at $pfZip" 'ERROR'
    } else {
        $pfDest = 'C:\Program Files (x86)\MitutoyoApp'
        Write-WTLog "Extracting $pfZip -> $pfDest"
        try {
            if (-not (Test-Path $pfDest)) { New-Item -Path $pfDest -ItemType Directory -Force | Out-Null }
            Expand-Archive -Path $pfZip -DestinationPath $pfDest -Force
            $count = (Get-ChildItem $pfDest -Recurse -File -ErrorAction SilentlyContinue).Count
            Write-WTLog "  extracted $count files"
        } catch {
            Write-WTLog "  Expand-Archive failed: $_" 'ERROR'
        }
    }

    if (Test-Path $maZip) {
        $maDest = 'C:\MitutoyoApp'
        Write-WTLog "Extracting $maZip -> $maDest"
        try {
            if (-not (Test-Path $maDest)) { New-Item -Path $maDest -ItemType Directory -Force | Out-Null }
            Expand-Archive -Path $maZip -DestinationPath $maDest -Force
        } catch {
            Write-WTLog "  Expand-Archive failed: $_" 'WARN'
        }
    }

    if (Test-Path $regGz) {
        $regOut = Join-Path $env:TEMP 'hklm-wow-mitutoyo.reg'
        Write-WTLog "Decompressing $regGz -> $regOut"
        try {
            $inGz = [IO.File]::OpenRead($regGz)
            $gz = New-Object IO.Compression.GZipStream($inGz, [IO.Compression.CompressionMode]::Decompress)
            $out = [IO.File]::Create($regOut)
            $gz.CopyTo($out)
            $out.Close(); $gz.Close(); $inGz.Close()
            Write-WTLog "Importing reg file via reg.exe /s"
            & reg.exe import $regOut 2>&1 | ForEach-Object { Write-WTLog "  reg: $_" }
            Write-WTLog "  reg import exit $LASTEXITCODE"
            Remove-Item $regOut -Force -ErrorAction SilentlyContinue
        } catch {
            Write-WTLog "  reg import failed: $_" 'ERROR'
        }
    }
}

# ============================================================================
# Step 3: Per-machine calibration ISO (mount + apply via cal Setup.exe)
# ============================================================================
# Cal ISOs are keyed by asset_tag. Read machine-number.txt to pick the right
# ISO. Each cal ISO is ~1.7MB and contains a tiny Mitutoyo wrapper Setup.exe
# plus data/*.txt compensation tables for the bay's specific probe + serial.
$mnPath = 'C:\Enrollment\machine-number.txt'
$asset = $null
if (Test-Path -LiteralPath $mnPath) {
    $asset = (Get-Content -LiteralPath $mnPath -First 1 -ErrorAction SilentlyContinue).Trim()
}
if (-not $asset) {
    Write-WTLog "machine-number.txt missing or empty - skipping calibration apply" 'WARN'
} else {
    $calDir = Join-Path $stagingRoot 'calibrations'
    $candidate = Get-ChildItem $calDir -Filter "CAL-${asset}_*.iso" -ErrorAction SilentlyContinue | Select-Object -First 1
    if (-not $candidate) {
        Write-WTLog "No cal ISO matched CAL-${asset}_*.iso in $calDir - skipping" 'WARN'
    } else {
        Write-WTLog "Mounting cal ISO: $($candidate.FullName)"
        try {
            $img = Mount-DiskImage -ImagePath $candidate.FullName -PassThru -ErrorAction Stop
            Start-Sleep -Seconds 2
            $calDrive = ($img | Get-Volume).DriveLetter
            Write-WTLog "  mounted at ${calDrive}:"
            $calSetup = "${calDrive}:\Setup.exe"
            if (Test-Path -LiteralPath $calSetup) {
                Write-WTLog "  running cal Setup.exe (may prompt - VB6 wrapper, same vintage as main installer)"
                # Cal ISO Setup.exe is tiny (135KB) - if it prompts, user has to click through.
                # Acceptable today; future: dark-deploy the data/*.txt files directly into
                # the FormTracePak data dir + skip Setup.exe.
                $p = Start-Process -FilePath $calSetup -WorkingDirectory "${calDrive}:\" -Wait -PassThru
                Write-WTLog "  cal Setup.exe exit $($p.ExitCode)"
            } else {
                Write-WTLog "  cal Setup.exe not found on ISO at $calSetup" 'WARN'
            }
            Dismount-DiskImage -ImagePath $candidate.FullName -ErrorAction SilentlyContinue | Out-Null
            Write-WTLog "  cal ISO dismounted"
        } catch {
            Write-WTLog "  Mount-DiskImage failed: $_" 'ERROR'
        }
    }
}

# ============================================================================
# Step 4: OpenText auto-start at login (HostExplorer "WJ Shopfloor" session)
# ============================================================================
$autoStartLib = Join-Path $PSScriptRoot '..\Shopfloor\lib\Set-OpenTextAutoStart.ps1'
if (Test-Path -LiteralPath $autoStartLib) {
    Write-WTLog "Calling $autoStartLib"
    & $autoStartLib
} else {
    Write-WTLog "Set-OpenTextAutoStart.ps1 not found at $autoStartLib - OpenText auto-start NOT configured" 'WARN'
}

if (Get-Command Send-PxeStatus -ErrorAction SilentlyContinue) {
    $finalStatus = if ($rc -eq 0) { 'in_progress' } else { 'failed' }
    $finalErr    = if ($rc -ne 0) { "Install-FromManifest exit $rc" } else { '' }
    Send-PxeStatus -Stage '09-Setup-WaxAndTrace: complete' -StageIndex 4 -StageTotal 8 -Status $finalStatus -Error_ $finalErr
}

Write-WTLog "================================================================"
Write-WTLog "=== WaxTrace Setup session end ==="
Write-WTLog "================================================================"

try { Stop-Transcript | Out-Null } catch {}