Backup Tool like the KUKA Backup USB Stick

    Hello All

    I am looking for a Standard backup tool for windows based machines.

    So far I have used the Clonezilla and the KUKA USB Stick (Only for kuka robots) and an internally developed Linux & NTFSClone based tool.

    Based on all the tools used, I find the KUKA Backup USB Stick to be more simple and user friendly.

    I want to check if such a tool or something better is available.

    The goal is, this tool should be usable by commissioning technicians to Developers and Managers if required.


    Simple GUI with easy options.

    If anyone came across such a tool or been using it currently provide details.

    Thank you

    This is for machines with Twincat 3 software. and other company specific tools.

    SW developed and tested in one maschine can then be written in series in maschine under production.

    Also if there is an issue at customer, the service techniker can create backup of separate disks and they can be examined/ issue can be recreated in back office.

    So, for Windows computers, then.

    Well, the first issue is going to be BIOS. A standard PC motherboard won't boot to USB unless the BIOS is configured that way. Some facilities are going to have strict rules regarding BIOS settings -- some even disable USB sockets on all computers for security reasons.

    Assuming that hurdle is overcome, it then becomes a choice of software. I've always preferred using CloneZilla, which has the advantages of being FOSS. And while I haven't automated it, I know that people have created automated backup/restore builds of CZ. And it's possible to build a virtual machine from a CZ backup image, which would make it easier to perform offline testing.

    That said, I do have to sound one note of warning: NVMe and M2 hard drives. I've recently had my first-ever failure of CZ to clone a Windows drive (Windows 10, I was trying to upgrade my laptop to a larger main drive). I was completely unable to figure out what the problem was. Attempts with Acronis and other cloning software also failed. The only thing I found that worked was to buy a Samsung NVMe drive and use Samsung's cloning utility. So testing your solution on all your hardware variations is strongly advised.

    That said, since these are "normal" Windows computers instead of robots, you may want to consider a different option. Rather than building a bootable USB backup/restore tool, you might want to look at the various "live" cloning software options, and simply include them as part of every machine. While I'm not personally familiar with them, I understand it's possible to create a clone of a Windows drive while Windows is running. Setting this up as a regular automated backup might eliminate some of the need for a USB-based solution.

    Quote from desertgiant

    SW developed and tested in one maschine can then be written in series in maschine under production.


    Also if there is an issue at customer, the service techniker can create backup of separate disks and they can be examined/ issue can be recreated in back office.

    Actually here you are talking about two differnt things:

    1. updating machines (which should go fast and smooth - do not forget to seal them)

    2. Customer support

    Finding any issues normally requires to get the exact copy of the hard drive (sector based copy) and for a quick updating normally file based copy is the thing (like kuka usb stick).

    So you would need one tool doing both things (or give your service technicians two tools)

    One of the mistakes i made in the past was simply back up a partition instead of the hard drive

    (hard drive will not boot because boot part is simply missing)

    Hi All

    Thanks for the inputs.

    Finally after searching through and testing, I found two tools to be matching closely the needs.

    Rescuezilla

    Redo Rescue

    Both are linux based but have a very good GUI.

    Rescuezilla is GUI version of Clonezilla and can restore clonezilla backups also. Individual Partitions can be backed up, but cannot be rewritten from the same disk. The backup must be moved to an external USB and then rewritten from this external usb to the disk drive. Compresssion option available.

    A Redo Rescue can save and restore backups from a different partition in the same diskdrive. Cloud backup and restore is also possible.

    Have tested through the weekend and works fine.

    However, if anyone used before and have faced issues with the tools let me know so that I can be aware of the issues.

    Once again, Thank you all.

    This is tested for Twincat3 Maschine and not recommended for KUKA Robots as I personally have not yet tested. For KUKA Robots, I would recommend the standard KUKA Gray USB stick.

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