Hi Mike,
Have you tried removing your Chrome temporarily, and then disable Cortana in services and re-enable it again with Chrome uninstalled? I remember you were having problems with that pre-AU on your test machine. There's been talk about a Cortana rebuild tool, but I cannot remember whether MS was going to provide it or not. Perhaps neem might be familiar with a script to do this.
I haven't used Cortana much at all due to the same problem you have, and that's once she's working it's difficult to keep her working.
What you might consider trying, is to use the
W10 PE console from your W10 bootable media, and run the
"Reset this PC" option, which is sort of like the "in-windows" version of
SFC /SCANNOW, except it's destructive and will remove all your programs and data. However, in the AU versions, I did notice that there is an option to
KEEP YOUR DATA FILES, which you might try. This hasn't fixed many problems for me, and I haven't attempted it with Cortana, but I remember it saying that it leaves your
PROGRAMS as well as your
DATA FILES alone and refreshes or replaces/overwrites any corrupted windows systems files many of which are library files which Cortana uses for it's audio interface as well as it's music location default directory.
I'm sorry there isn't a better fix out there for this, and hopefully MS may make a Cortana option of their Fix-It tool. I know you do Image backups using EASEus ToDo, so it might make sense to give the
"Reset this PC" option a try, and see if it fixes Cortana or not. If it does, it would be only slightly better than a complete W10 reinstallation via Clean Install and the traditional In-Place upgrade we're use to with earlier versions of windows (W7/W8x). If it fixes it, you could run for a week or so without Chrome making sure Cortana is working by testing daily when you get up for that first cup of Coffee and asking her to play your favorite song or tell you a joke. Then if all is well after a week, reinstall your Chrome and see if the fix sticks. If it does, you're good to go for now at least!
The next thing I'd be concerned about, is how stable this fix is as you say, once you get it working she soon stops. What we might recommend is that if she's working for a month or 2, go into WU as well as WUDO and turn both those options off *if you haven't already done so* to keep driver updates or windows system files security updates to mess with Cortana services and or library GPO settings.
Take a look at these 2 links:
1.) WU UPDATE DRIVER DISABLE: https://support.microsoft.com/en-us/kb/3073930#bookmark-1607
2.) WUDO DISABLE INSTRUCTIONS: Windows Update Delivery Optimization: FAQ
Over the last few months, Ross, neem, pnamajck, and myself have been recommending using these 2 settings for forum users who post various problems that appear to be due to MS updates scrambling either their drivers *often Wi-Fi, or GPU card drivers* and losing functionality there as well as weird audio problems. I know you read the W10 threads quite a bit, and we've tried this and it works better, but doesn't completely block W10 updates on all machines from messing things up, but it does seem to help. I've now got 8-W10 machines and I've got all of them but 1 new machine running in this fashion. I think it might be worth it to try it out on your primary daily driver computer (your self-built gaming PC?) and see if it mitigates Cortana from going comatose on you. Report back and let us know if you have any luck, or it makes any difference at all.
One thing I noticed from my last trip out of town at the beginning of this month, December, when I returned home I flipped on my main W10 test machine (which has 4 drives in it), and all 3 of the W10 drives I have (2 of them with v1607 AU, and 1 of them with v1511 pre-Au) mysteriously wouldn't work, and I had to repair all 3 of them that run in this state. I didn't fully research the Update History to nail down whether a WUDO or WU update got loose on my LAN and scrambled all of these, I just wanted them working again as I have a couple of projects I was doing and just wanted to finish those. So I restored Image backups I made in Macrium from August when I built all the drives and put them back to where all 3 were working in individual boot mode. Then I re-cabled all 3 drives back up to the Mobo and tested their ability to boot using <F12> boot preference order to select each drive; which is all working again. I just thought that rather odd, so I'd mention it. It might be completely unrelated to the Cortana problem; I don't know. But, more information for everyone else to look at who are following W10 AU issues.
Well, good luck, and BTW how is your weather back there? We are finally getting some good snow here in SoCal!
Merry Christmas and Happy New Year!
<<<BBJ>>>