[modbus] Build single-value register writes on a right-sized stack buffer (#18844)

Co-authored-by: J. Nick Koston <nick@koston.org>

esphome/components/modbus/modbus.h

@@ -534,6 +534,9 @@ class ModbusClientDevice {
     return this->queue_pdu(helpers::create_write_single_coil_pdu(address, value));
   }
   bool write_multiple_registers(uint16_t start_address, std::span<const uint16_t> values) {
+    // Empty goes to the full-size builder so the rejection log names this method's limit, not the small one's.
+    if (!values.empty() && values.size() <= helpers::MAX_FEW_REGISTERS)
+      return this->queue_pdu(helpers::create_write_few_registers_pdu(start_address, values));
     return this->queue_pdu(helpers::create_write_registers_pdu(start_address, values));
   }
   /// Note: std::vector<bool> cannot bind to std::span<const bool>; use a contiguous bool container or the packed

esphome/components/modbus/modbus_definitions.h

@@ -116,6 +116,9 @@ static constexpr uint16_t MAX_RAW_SIZE = 254;  // Max RAW size is 256 - CRC(2) =
 static constexpr uint16_t READ_PDU_SIZE = 5;
 // A single-write PDU is always function code(1) + address(2) + value(2)
 static constexpr uint16_t WRITE_SINGLE_PDU_SIZE = 5;
+// A multiple-write PDU starts with function code(1) + start address(2) + quantity(2) + byte count(1),
+// followed by two bytes per register.
+static constexpr uint16_t WRITE_MULTIPLE_HEADER_SIZE = 6;
 static constexpr uint16_t MAX_FRAME_SIZE = 256;
 
 // 4.1 Address 0 is the broadcast address: the request is processed by every device and never answered.

esphome/components/modbus/modbus_helpers.cpp

@@ -485,9 +485,12 @@ static bool register_block_in_range(const LogString *role, uint16_t start_addres
   return true;
 }
 
-PduBuffer create_write_registers_pdu(uint16_t start_address, std::span<const uint16_t> values) {
-  PduBuffer pdu;  // declared before every return so NRVO fires (all paths return the same object)
-  if (!register_block_in_range(LOG_STR("Write"), start_address, values.size(), MAX_NUM_OF_REGISTERS_TO_WRITE)) {
+// The ceiling comes from the buffer itself: push_back() drops silently, so a bound wider than the buffer
+// would put a truncated frame on the wire.
+template<typename Pdu> static Pdu build_write_registers_pdu(uint16_t start_address, std::span<const uint16_t> values) {
+  constexpr auto max_registers = static_cast<uint16_t>((Pdu::capacity() - WRITE_MULTIPLE_HEADER_SIZE) / 2);
+  Pdu pdu;  // declared before every return so NRVO fires (all paths return the same object)
+  if (!register_block_in_range(LOG_STR("Write"), start_address, values.size(), max_registers)) {
     return pdu;
   }
   append_pdu_header(pdu, FunctionCode::WRITE_MULTIPLE_REGISTERS, start_address, values.size());
@@ -498,6 +501,19 @@ PduBuffer create_write_registers_pdu(uint16_t start_address, std::span<const uin
   return pdu;
 }
 
+static_assert((PduBuffer::capacity() - WRITE_MULTIPLE_HEADER_SIZE) / 2 == MAX_NUM_OF_REGISTERS_TO_WRITE,
+              "a full-frame PDU must hold exactly MAX_NUM_OF_REGISTERS_TO_WRITE registers");
+static_assert((WriteFewRegistersPdu::capacity() - WRITE_MULTIPLE_HEADER_SIZE) / 2 == MAX_FEW_REGISTERS,
+              "the small write buffer must hold exactly MAX_FEW_REGISTERS registers");
+
+PduBuffer create_write_registers_pdu(uint16_t start_address, std::span<const uint16_t> values) {
+  return build_write_registers_pdu<PduBuffer>(start_address, values);
+}
+
+WriteFewRegistersPdu create_write_few_registers_pdu(uint16_t start_address, std::span<const uint16_t> values) {
+  return build_write_registers_pdu<WriteFewRegistersPdu>(start_address, values);
+}
+
 PduBuffer create_read_write_multiple_registers_pdu(uint16_t read_start_address, uint16_t read_count,
                                                    uint16_t write_start_address,
                                                    std::span<const uint16_t> write_values) {

esphome/components/modbus/modbus_helpers.h

@@ -473,11 +473,15 @@ inline int64_t payload_to_number(const std::vector<uint8_t> &data, SensorValueTy
  */
 std::optional<int64_t> registers_to_number(const uint16_t *registers, size_t count, SensorValueType sensor_value_type);
 
+/// The widest standard numeric value (a QWORD) spans 4 registers, so one entity value never writes more.
+static constexpr uint16_t MAX_FEW_REGISTERS = 4;
+
 // Named PDU buffer types: the builders' storage strategy (currently stack-allocated StaticVector,
 // right-sized per shape) can be swapped in one place without touching every signature.
 using PduBuffer = StaticVector<uint8_t, MAX_PDU_SIZE>;
 using ReadPdu = StaticVector<uint8_t, READ_PDU_SIZE>;
 using WriteSinglePdu = StaticVector<uint8_t, WRITE_SINGLE_PDU_SIZE>;
+using WriteFewRegistersPdu = StaticVector<uint8_t, WRITE_MULTIPLE_HEADER_SIZE + 2 * MAX_FEW_REGISTERS>;
 /// Scratch space for packing coils into wire layout: one bit per coil, sized for the spec maximum.
 using CoilPackBuffer = StaticVector<uint8_t, packed_bit_bytes(MAX_NUM_OF_COILS_TO_WRITE)>;
 
@@ -521,6 +525,15 @@ PduBuffer create_client_pdu(FunctionCode function_code, uint16_t start_address,
  */
 PduBuffer create_write_registers_pdu(uint16_t start_address, std::span<const uint16_t> values);
 
+/** Create modbus write multiple registers command (function 0x10) on a right-sized stack buffer.
+ * Identical wire bytes to create_write_registers_pdu() for any accepted input.
+ * @param start_address modbus address of the first register to write
+ * @param values register values to write, at most MAX_FEW_REGISTERS (an over-long or empty set is
+ *               rejected and an empty PDU is returned)
+ * @return PDU (function code + data, no address, no CRC)
+ */
+WriteFewRegistersPdu create_write_few_registers_pdu(uint16_t start_address, std::span<const uint16_t> values);
+
 /** Create modbus read/write multiple registers command
  *  Function 0x17 Read/Write Multiple Registers
  * Writes write_values then reads read_count registers in one transaction (write first, per Modbus 6.17);

esphome/core/helpers.h

@@ -290,6 +290,7 @@ template<typename T, size_t N> class StaticVector {
   }
 
   size_t size() const { return count_; }
+  static constexpr size_t capacity() { return N; }
   bool empty() const { return count_ == 0; }
 
   // Direct access to underlying data