This works! The only real change I've made is to ensure that the 'destringification' of the process object only happens once:

$ProcessObj ||= eval($ProcessObj_as_string);
[download]

Why it works is still something of a mystery to me, but maybe it will help you forward with your investigations.

#!perl -slw
use strict;
use threads;
use threads::shared;
use Thread::Queue;

use Win32::Process;
use Win32;

use Data::Dumper;

sub ErrorReport { print Win32::FormatMessage( Win32::GetLastError() );
+ }

## A shared var to communicate progess between work thread and TK
my $Q = new Thread::Queue;
my $ProcessObj_as_string:shared;
my $ProcessObj;

sub work{
    # save STDOUT
    open(my $STDOUT_ORIG, ">&", \*STDOUT) or die;

    # connect TO_CHILD_PROC with CHILD_PROC
    pipe(CHILD_PROC, TO_CHILD_PROC);

    # change STDOUT to TO_CHILD_PROC
    # --> STDOUT of child process is set to TO_CHILD_PROC and
    #     this is connected via pipe with CHILD_PROC
    open(STDOUT, ">&", \*TO_CHILD_PROC);

    Win32::Process::Create(
        $ProcessObj, "C:\\Perl32\\bin\\perl.exe", "perl child.pl",
        1, NORMAL_PRIORITY_CLASS, "."
    )|| die "$! : $^E";

    warn "$ProcessObj $$ProcessObj";
    $ProcessObj_as_string = Dumper($ProcessObj);

    # restore STDOUT
    open(STDOUT, ">&", $STDOUT_ORIG) or die;

    while( <CHILD_PROC> ) {
        chomp($_);
        $Q->enqueue( $_ );
    }

    close( CHILD_PROC );
}

threads->new( \&work )->detach;

use Tk;
use Tk::ProgressBar;

my $mw = MainWindow->new;
my $pb = $mw->ProgressBar()->pack();

my $repeat;
$repeat = $mw->repeat(
    100 => sub {
        while( $Q->pending ) {
            my $progress = $Q->dequeue;
            return unless $progress;
            $repeat->cancel if $progress == 100;
            $pb->value( $progress );
        }
    }
);

$mw->Button(
    '-text' => 'Cancel', '-command' => sub {
        my $VAR1;
        $ProcessObj ||= eval($ProcessObj_as_string);
        warn "$ProcessObj $$ProcessObj";
        $ProcessObj->Kill(0);
        exit 0;
    }
)->pack();

$mw->Button(
    '-text' => 'Suspend', '-command' => sub {
        my $VAR1;
        $ProcessObj ||= eval($ProcessObj_as_string);
        warn "$ProcessObj $$ProcessObj";
        $ProcessObj->Suspend();
    }
)->pack();

$mw->Button(
    '-text' => 'Resume', '-command' => sub {
        my $VAR1;
        $ProcessObj ||= eval($ProcessObj_as_string);
        warn "$ProcessObj $$ProcessObj";
        $ProcessObj->Resume();
    }
)->pack();

$mw->MainLoop;
[download]

To understand why I tried it, try running your original code, but immediately suspend the child using the Process Explorer, then you'll find that the resume will work via your Tk interface. Exactly once.

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