fix(gateway): resolve startup hang caused by qqbot plugin manifest ID mismatch & stderr flood (#718)

electron/gateway/config-sync.ts

@@ -20,7 +20,7 @@ import { getApiKey, getDefaultProvider, getProvider } from '../utils/secure-stor
 import { getProviderEnvVar, getKeyableProviderTypes } from '../utils/provider-registry';
 import { getOpenClawDir, getOpenClawEntryPath, isOpenClawPresent } from '../utils/paths';
 import { getUvMirrorEnv } from '../utils/uv-env';
-import { cleanupDanglingWeChatPluginState, listConfiguredChannels } from '../utils/channel-config';
+import { cleanupDanglingWeChatPluginState, listConfiguredChannels, readOpenClawConfig } from '../utils/channel-config';
 import { syncGatewayTokenToConfig, syncBrowserConfigToOpenClaw, syncSessionIdleMinutesToOpenClaw, sanitizeOpenClawConfig } from '../utils/openclaw-auth';
 import { buildProxyEnv, resolveProxySettings } from '../utils/proxy';
 import { syncProxyConfigToOpenClaw } from '../utils/openclaw-proxy';
@@ -131,6 +131,10 @@ function ensureConfiguredPluginsUpgraded(configuredChannels: string[]): void {
         } catch (err) {
           logger.warn(`[plugin] Failed to ${isInstalled ? 'auto-upgrade' : 'install'} ${channelType} plugin:`, err);
         }
+      } else if (isInstalled) {
+        // Same version already installed — still patch manifest ID in case it was
+        // never corrected (e.g. installed before MANIFEST_ID_FIXES included this plugin).
+        fixupPluginManifest(targetDir);
       }
       continue;
     }
@@ -141,10 +145,14 @@ function ensureConfiguredPluginsUpgraded(configuredChannels: string[]): void {
       if (!existsSync(fsPath(join(npmPkgPath, 'openclaw.plugin.json')))) continue;
       const sourceVersion = readPluginVersion(join(npmPkgPath, 'package.json'));
       if (!sourceVersion) continue;
-      // Skip only if installed AND same version
-      if (isInstalled && installedVersion && sourceVersion === installedVersion) continue;
+      // Skip only if installed AND same version — but still patch manifest ID.
+      if (isInstalled && installedVersion && sourceVersion === installedVersion) {
+        fixupPluginManifest(targetDir);
+        continue;
+      }
 
       logger.info(`[plugin] ${isInstalled ? 'Auto-upgrading' : 'Installing'} ${channelType} plugin${isInstalled ? `: ${installedVersion} → ${sourceVersion}` : `: ${sourceVersion}`} (dev/node_modules)`);
+
       try {
         mkdirSync(fsPath(join(homedir(), '.openclaw', 'extensions')), { recursive: true });
         copyPluginFromNodeModules(npmPkgPath, targetDir, npmName);
@@ -187,6 +195,34 @@ export async function syncGatewayConfigBeforeLaunch(
   // the plugin manifest ID matches what sanitize wrote to the config.
   try {
     const configuredChannels = await listConfiguredChannels();
+
+    // Also ensure plugins referenced in plugins.allow are installed even if
+    // they have no channels.X section yet (e.g. qqbot added via plugins.allow
+    // but never fully saved through ClawX UI).
+    try {
+      const rawCfg = await readOpenClawConfig();
+      const allowList = Array.isArray(rawCfg.plugins?.allow) ? (rawCfg.plugins!.allow as string[]) : [];
+      // Build reverse maps: dirName → channelType AND known manifest IDs → channelType
+      const pluginIdToChannel: Record<string, string> = {};
+      for (const [channelType, info] of Object.entries(CHANNEL_PLUGIN_MAP)) {
+        pluginIdToChannel[info.dirName] = channelType;
+      }
+      // Known manifest IDs that differ from their dirName/channelType
+      pluginIdToChannel['openclaw-qqbot'] = 'qqbot';
+      pluginIdToChannel['openclaw-lark'] = 'feishu';
+      pluginIdToChannel['feishu-openclaw-plugin'] = 'feishu';
+
+      for (const pluginId of allowList) {
+        const channelType = pluginIdToChannel[pluginId] ?? pluginId;
+        if (CHANNEL_PLUGIN_MAP[channelType] && !configuredChannels.includes(channelType)) {
+          configuredChannels.push(channelType);
+        }
+      }
+
+    } catch (err) {
+      logger.warn('[plugin] Failed to augment channel list from plugins.allow:', err);
+    }
+
     ensureConfiguredPluginsUpgraded(configuredChannels);
   } catch (err) {
     logger.warn('Failed to auto-upgrade plugins:', err);

electron/gateway/manager.ts

@@ -705,6 +705,9 @@ export class GatewayManager extends EventEmitter {
     await unloadLaunchctlGatewayService();
     this.processExitCode = null;
 
+    // Per-process dedup map for stderr lines — resets on each new spawn.
+    const stderrDedup = new Map<string, number>();
+
     const { child, lastSpawnSummary } = await launchGatewayProcess({
       port: this.status.port,
       launchContext,
@@ -715,6 +718,18 @@ export class GatewayManager extends EventEmitter {
         recordGatewayStartupStderrLine(this.recentStartupStderrLines, line);
         const classified = classifyGatewayStderrMessage(line);
         if (classified.level === 'drop') return;
+
+        // Dedup: suppress identical stderr lines after the first occurrence.
+        const count = (stderrDedup.get(classified.normalized) ?? 0) + 1;
+        stderrDedup.set(classified.normalized, count);
+        if (count > 1) {
+          // Log a summary every 50 duplicates to stay visible without flooding.
+          if (count % 50 === 0) {
+            logger.debug(`[Gateway stderr] (suppressed ${count} repeats) ${classified.normalized}`);
+          }
+          return;
+        }
+
         if (classified.level === 'debug') {
           logger.debug(`[Gateway stderr] ${classified.normalized}`);
           return;

electron/gateway/startup-stderr.ts

@@ -30,6 +30,9 @@ export function classifyGatewayStderrMessage(message: string): GatewayStderrClas
   if (msg.includes('DeprecationWarning')) return { level: 'debug', normalized: msg };
   if (msg.includes('Debugger attached')) return { level: 'debug', normalized: msg };
 
+  // Gateway config warnings (e.g. stale plugin entries) are informational, not actionable.
+  if (msg.includes('Config warnings:')) return { level: 'debug', normalized: msg };
+
   // Electron restricts NODE_OPTIONS in packaged apps; this is expected and harmless.
   if (msg.includes('node: --require is not allowed in NODE_OPTIONS')) {
     return { level: 'debug', normalized: msg };