Openclaw crashes right after sending a message

[yangyishuo1124]

DomainUnhandledException
System.DllNotFoundException: Unable to load DLL 'sherpa-onnx-c-api' or one of its dependencies: 动态链接库(DLL)初始化例程失败。 (0x8007045A)
at SherpaOnnx.OfflineTts.SherpaOnnxDestroyOfflineTts(IntPtr handle)
at SherpaOnnx.OfflineTts.SherpaOnnxDestroyOfflineTts(IntPtr handle)
at SherpaOnnx.OfflineTts.Cleanup()
at SherpaOnnx.OfflineTts.Finalize()
at System.GC.RunFinalizers()

[clawsweeper]

Thanks for the context here. I did a careful shell check against current main, and this is already implemented.

Current main already contains the merged native dependency fix for the exact 0x8007045A Sherpa/ONNX OfflineTts finalizer crash reported in #703; the fix is current-main-only and is not included in v0.6.3.

I found the merged PR that appears to have closed this: #713: Fix tray crash-loop: source x64 VC++ runtime from VS install at publish time.

So I’m closing this as already implemented rather than keeping a duplicate issue open.

Review details

Best possible solution:

Keep the current-main VC runtime packaging and Sherpa/ONNX native stack verifier fix, then ship it in the next release so affected v0.6.3 users receive the repair.

Do we have a high-confidence way to reproduce the issue?

Yes, with source-level confidence: the stack exactly matches the canonical Sherpa/ONNX native dependency report, and current source routes Piper TTS through OfflineTts. I did not run a Windows packaged repro during this read-only review.

Is this the best way to solve the issue?

Yes. The current-main solution fixes the root packaging problem by sourcing a new enough VC runtime and adding a Sherpa/ONNX native stack release probe, which is narrower than adding a TTS workaround while leaving stale app-local runtime DLLs in shipped payloads.

Security review:

Security review: No PR patch is under review, and the issue is not a security report.

AGENTS.md: found, but no applicable review policy affected this item.

What I checked:

• Reported stack matches existing canonical crash: The earlier closed report contains the same sherpa-onnx-c-api 0x8007045A OfflineTts finalizer stack and says replacing the stale app-local VC runtime fixes the crash.
• Current TTS source path: Current main still routes Piper text-to-speech through new OfflineTts(config), confirming the reported stack is the local Sherpa-backed TTS provider path. (src/OpenClaw.Tray.WinUI/Services/TextToSpeech/PiperTextToSpeechClient.cs:56, ff38d8499c48)
• Current main native dependency fix: Current main sources x64 VC runtime DLLs from the Visual Studio redist path at publish time instead of keeping the stale NuGet-sourced runtime that caused the Sherpa/ONNX load failure. (src/Directory.Build.targets:59, 8bf605cdbd32)
• Current main native stack validation: The release verifier now requires sherpa-onnx-c-api.dll, onnxruntime.dll, and Microsoft.ML.OnnxRuntime.dll, runs an isolated TTS native stack probe, and documents that stale VC runtime DLLs cause 0x8007045A. (scripts/Test-ReleaseNativeDependencies.ps1:143, ff38d8499c48)
• Fix provenance: Merged pull request Fix tray crash-loop: source x64 VC++ runtime from VS install at publish time #713 closed the canonical crash report, and the squash commit is 8bf605cdbd3289bb1bb8fbc4daff8a13170c66bf with timestamp 2026-06-07T15:29:01-07:00. (8bf605cdbd32)
• Release provenance: No tag contains the fix commit, and git merge-base --is-ancestor 8bf605cd v0.6.3 returned 1, so the fix is present on current main but not in v0.6.3. (8bf605cdbd32)

Likely related people:

• shanselman: Co-authored the TTS native stack probe commits in the merged fix PR and posted the Windows x64 publish/verifier proof before merge. (role: recent area contributor; confidence: high; commits: c45d2b62f604, 4ff5166d165f, 4eb848b09bba; files: scripts/Test-ReleaseNativeDependencies.ps1, src/Directory.Build.targets, tests/OpenClaw.Tray.Tests/ReleaseSigningWorkflowTests.cs)
• Vincent Koc: Introduced the VC runtime bundling and native dependency verifier path later fixed for this crash class. (role: introduced release runtime bundling; confidence: high; commits: 7485ce2af9da; files: src/Directory.Build.props, src/Directory.Build.targets, scripts/Test-ReleaseNativeDependencies.ps1)
• Keith Mahoney: Recently changed adjacent ARM64 VC runtime publish logic and release tests in the same packaging area. (role: recent release-runtime contributor; confidence: medium; commits: f839cf53aa0c; files: src/Directory.Build.targets, tests/OpenClaw.Tray.Tests/ReleaseSigningWorkflowTests.cs, docs/RELEASING.md)
• Régis Brid: Introduced the Sherpa package reference and Piper OfflineTts wrapper involved in the reported native initialization/finalizer stack. (role: introduced Sherpa/Piper TTS path; confidence: high; commits: b0ba9affa25d, e0c40985a718; files: src/OpenClaw.Tray.WinUI/OpenClaw.Tray.WinUI.csproj, src/OpenClaw.Tray.WinUI/Services/TextToSpeech/PiperTextToSpeechClient.cs, src/OpenClaw.Shared/Audio/PiperVoiceManager.cs)

Codex review notes: model internal, reasoning high; reviewed against ff38d8499c48; fix evidence: merged PR #713, commit 8bf605cdbd32, main fix timestamp 2026-06-07T15:29:01-07:00.