Raise host frame payload limit so multi-client UART replies fit.

Use a uint16 LE length and 1024-byte max payload so CLIENT_INFO and BATTERY_STATUS no longer fail encoding past ~10 connected pods.

Co-authored-by: Cursor <cursoragent@cursor.com>

docs/ARCHITECTURE.md

@@ -225,12 +225,12 @@ Unabhängig von Protobuf — reines Bytestream-Framing:
 | Feld | Wert |
 |------|------|
 | Start | `0xAA` |
-| Länge | 1 Byte (1–252) |
+| Länge | 2 Bytes little-endian (1–1024) |
 | Payload | `length` Bytes |
 | Prüfsumme | XOR aller Payload-Bytes |
 | Stopp | `0xCC` |
 
-**Parameter:** `main/uart.h` — `UART_NUM_1`, `921600` Baud, TX GPIO **2**, RX GPIO **3**, `MAX_PAYLOAD_SIZE` 248.
+**Parameter:** `main/uart.h` — `UART_NUM_1`, `921600` Baud, TX GPIO **2**, RX GPIO **3**, `MAX_PAYLOAD_SIZE` 1024.
 
 ### 5.2 Nutzlast (Anwendung)
 

docs/DOCUMENTATION.md

@@ -124,10 +124,10 @@ idf.py -p /dev/ttyUSB0 flash monitor
 | Byte | Inhalt |
 |------|--------|
 | 0 | `0xAA` Start |
-| 1 | Länge N (1–252) |
+| 1–2 | Länge N little-endian (1–1024) |
-| 2…N+1 | Payload |
+| 3…N+2 | Payload |
-| N+2 | XOR-Checksum über Payload |
+| N+3 | XOR-Checksum über Payload |
-| N+3 | `0xCC` Stopp |
+| N+4 | `0xCC` Stopp |
 
 Implementierung: `uart.c` — `parse_uart_byte()`, `uart_send_framed()`.
 

docs/adding-a-feature.md

@@ -287,7 +287,7 @@ Entspricht `main/README.md`:
 
 | Byte | Inhalt |
 |------|--------|
-| Frame | `0xAA`, Länge, Payload, XOR-Checksum, `0xCC` |
+| Frame | `0xAA`, Länge (uint16 LE), Payload, XOR-Checksum, `0xCC` |
 | Payload[0] | `MessageType` (z.B. `22` = FIND_ME) |
 | Payload[1…] | Nanopb-`UartMessage` |
 

goTool/uart/frame.go

@@ -10,8 +10,10 @@ import (
 const (
 	StartMarker = 0xAA
 	StopMarker  = 0xCC
-	// Must match main/uart.h MAX_PAYLOAD_SIZE (MAX_BUF_SIZE - 4).
+	// Must match main/uart.h MAX_PAYLOAD_SIZE.
-	MaxPayload = 248
+	MaxPayload = 1024
+	// AA | len_lo | len_hi | payload | xor | CC
+	FrameOverhead = 5
 )
 
 var (
@@ -19,14 +21,15 @@ var (
 	ErrTimeout      = errors.New("read timeout")
 )
 
-// EncodeFrame builds a framed packet: 0xAA len payload xor(payload) 0xCC.
+// EncodeFrame builds a framed packet: 0xAA len_lo len_hi payload xor(payload) 0xCC.
 func EncodeFrame(payload []byte) ([]byte, error) {
 	if len(payload) == 0 || len(payload) > MaxPayload {
 		return nil, fmt.Errorf("payload length %d out of range 1..%d", len(payload), MaxPayload)
 	}
 
-	frame := make([]byte, 0, 4+len(payload))
+	n := len(payload)
-	frame = append(frame, StartMarker, byte(len(payload)))
+	frame := make([]byte, 0, FrameOverhead+n)
+	frame = append(frame, StartMarker, byte(n&0xff), byte((n>>8)&0xff))
 	var checksum byte
 	for _, b := range payload {
 		frame = append(frame, b)
@@ -39,6 +42,7 @@ func EncodeFrame(payload []byte) ([]byte, error) {
 type Parser struct {
 	state    int
 	len      int
+	lenLo    byte
 	payload  []byte
 	index    int
 	checksum byte
@@ -46,7 +50,8 @@ type Parser struct {
 
 const (
 	stateStart = iota
-	stateLen
+	stateLenLo
+	stateLenHi
 	stateData
 	stateChecksum
 	stateStop
@@ -63,14 +68,19 @@ func (p *Parser) Feed(b byte) (payload []byte, ok bool, err error) {
 		if b == StartMarker {
 			p.index = 0
 			p.checksum = 0
-			p.state = stateLen
+			p.state = stateLenLo
 		}
-	case stateLen:
+	case stateLenLo:
-		if b == 0 || b > MaxPayload {
+		p.lenLo = b
+		p.state = stateLenHi
+	case stateLenHi:
+		n := int(p.lenLo) | (int(b) << 8)
+		if n == 0 || n > MaxPayload {
 			p.state = stateStart
 		} else {
-			p.len = int(b)
+			p.len = n
 			p.payload = make([]byte, p.len)
+			p.index = 0
 			p.state = stateData
 		}
 	case stateData:
@@ -102,7 +112,7 @@ func (p *Parser) Feed(b byte) (payload []byte, ok bool, err error) {
 // maxWait bounds total wait time; zero means no limit (serial read timeouts retry forever).
 func ReadFrame(r io.Reader, buf []byte, maxWait time.Duration) ([]byte, error) {
 	if buf == nil {
-		buf = make([]byte, 256)
+		buf = make([]byte, 1024)
 	}
 	parser := NewParser()
 

main/README.md

@@ -166,7 +166,7 @@ Hardware: **UART1**, **921600** baud, **TX = GPIO3**, **RX = GPIO2** (adapter TX
 | Field | Value |
 |-------|--------|
 | Start | `0xAA` |
-| Length | 1 byte, payload size 1–252 |
+| Length | 2 bytes little-endian, payload size 1–1024 |
 | Payload | `length` bytes |
 | Checksum | XOR of all payload bytes |
 | Stop | `0xCC` |
@@ -178,7 +178,7 @@ Hardware: **UART1**, **921600** baud, **TX = GPIO3**, **RX = GPIO2** (adapter TX
 | 0 | Command ID (`MessageType` / `msg_id`) |
 | 1… | Arguments (handler receives bytes after ID only) |
 
-Example VERSION request: single-byte payload `03` → frame `AA 01 03 03 CC`.
+Example VERSION request: single-byte payload `03` → frame `AA 01 00 03 03 CC`.
 
 Logging:
 

main/ble_stream.c

@@ -113,8 +113,8 @@ static esp_err_t send_tick_truncated(alox_UartMessage *msg) {
 
     size_t payload_len = stream.bytes_written + 1;
     uint16_t max_pay = ble_host_max_payload();
-    /* Framed size = payload + 4; notify must fit ATT MTU-3. */
+    /* Framed size = payload + UART_FRAME_OVERHEAD; notify must fit ATT MTU-3. */
-    size_t frame_len = payload_len + 4;
+    size_t frame_len = payload_len + UART_FRAME_OVERHEAD;
     if (payload_len <= MAX_PAYLOAD_SIZE && frame_len <= max_pay) {
       uint8_t payload[MAX_PAYLOAD_SIZE];
       payload[0] = (uint8_t)msg->type;
@@ -197,7 +197,7 @@ void ble_stream_update(void) {
 
   if (want && !s_running) {
     s_running = true;
-    if (xTaskCreate(ble_stream_task, "ble_stream", 4096, NULL, 5, &s_task) !=
+    if (xTaskCreate(ble_stream_task, "ble_stream", 8192, NULL, 5, &s_task) !=
         pdPASS) {
       s_running = false;
       s_task = NULL;

main/host_transport.c

@@ -22,14 +22,14 @@ void host_transport_set_cmd_queue(QueueHandle_t cmd_queue) {
 
 QueueHandle_t host_transport_cmd_queue(void) { return s_cmd_queue; }
 
-bool host_enqueue_packet(const uint8_t *payload, uint8_t len) {
+bool host_enqueue_packet(const uint8_t *payload, size_t len) {
   if (s_cmd_queue == NULL || payload == NULL || len == 0) {
     return false;
   }
 
   generic_msg_t msg = {
       .msg_id = payload[0],
-      .len = len > 1 ? (size_t)(len - 1) : 0,
+      .len = len > 1 ? (len - 1) : 0,
       .payload = NULL,
   };
 
@@ -63,10 +63,11 @@ esp_err_t host_send_framed(const uint8_t *payload, size_t len) {
     checksum ^= payload[i];
   }
 
-  uint8_t frame[4 + MAX_PAYLOAD_SIZE];
+  uint8_t frame[UART_FRAME_OVERHEAD + MAX_PAYLOAD_SIZE];
   size_t pos = 0;
   frame[pos++] = START_MARKER;
-  frame[pos++] = (uint8_t)len;
+  frame[pos++] = (uint8_t)(len & 0xff);
+  frame[pos++] = (uint8_t)((len >> 8) & 0xff);
   memcpy(&frame[pos], payload, len);
   pos += len;
   frame[pos++] = checksum;

main/host_transport.h

@@ -19,7 +19,7 @@ void host_transport_set_cmd_queue(QueueHandle_t cmd_queue);
 QueueHandle_t host_transport_cmd_queue(void);
 
 /**
- * Build AA|len|payload|xor|CC and send via the registered TX backend.
+ * Build AA|len_lo|len_hi|payload|xor|CC and send via the registered TX backend.
  * Same semantics as uart_send_framed.
  */
 esp_err_t host_send_framed(const uint8_t *payload, size_t len);
@@ -31,6 +31,6 @@ esp_err_t host_send_framed(const uint8_t *payload, size_t len);
 void host_rx_bytes(const uint8_t *data, size_t len);
 
 /** Enqueue a completed uart_packet_t (payload[0]=msg type). */
-bool host_enqueue_packet(const uint8_t *payload, uint8_t len);
+bool host_enqueue_packet(const uint8_t *payload, size_t len);
 
 #endif

main/uart.c

@@ -81,18 +81,27 @@ bool parse_uart_byte(uint8_t byte, uart_packet_t *p) {
     if (byte == START_MARKER) {
       p->index = 0;
       p->checksum = 0;
-      p->state = STATE_LEN;
+      p->len = 0;
+      p->state = STATE_LEN_LO;
     }
     break;
 
-  case STATE_LEN:
+  case STATE_LEN_LO:
-    if (byte > MAX_PAYLOAD_SIZE || byte == 0) {
+    p->len = byte;
+    p->state = STATE_LEN_HI;
+    break;
+
+  case STATE_LEN_HI: {
+    uint16_t len = (uint16_t)(p->len | ((uint16_t)byte << 8));
+    if (len == 0 || len > MAX_PAYLOAD_SIZE) {
       p->state = STATE_START;
     } else {
-      p->len = byte;
+      p->len = len;
+      p->index = 0;
       p->state = STATE_DATA;
     }
     break;
+  }
 
   case STATE_DATA:
     p->payload[p->index++] = byte;

main/uart.h

@@ -22,13 +22,18 @@
 #define UART_DRIVER_TX_BUF_SIZE 4096
 #define START_MARKER 0xAA
 #define STOP_MARKER 0xCC
-#define MAX_BUF_SIZE 252
+/** Frame: AA | len_lo | len_hi | payload[len] | xor | CC */
-#define MAX_PAYLOAD_SIZE                                                       \
+#define UART_FRAME_OVERHEAD 5
-  MAX_BUF_SIZE - 4 // Buffer overhead, Start, Len, CRC, End
+/**
+ * Max application payload (type byte + protobuf). Sized for CLIENT_REGISTRY_MAX
+ * aggregations (CLIENT_INFO / BATTERY_STATUS with 16+ samples).
+ */
+#define MAX_PAYLOAD_SIZE 1024
 
 typedef enum {
   STATE_START,
-  STATE_LEN,
+  STATE_LEN_LO,
+  STATE_LEN_HI,
   STATE_DATA,
   STATE_CHECKSUM,
   STATE_STOP
@@ -36,8 +41,8 @@ typedef enum {
 
 typedef struct {
   uint8_t payload[MAX_PAYLOAD_SIZE];
-  uint8_t len;
+  uint16_t len;
-  uint8_t index;
+  uint16_t index;
   uint8_t checksum;
   parser_state_t state;
 } uart_packet_t;

main/uart_proto.c

@@ -1,18 +1,26 @@
 #include "uart_proto.h"
+#include "esp_log.h"
 #include "pb_encode.h"
 #include "uart.h"
 #include <string.h>
 
+static const char *TAG = "[UART_PROTO]";
+
 esp_err_t uart_send_uart_message(const alox_UartMessage *msg) {
   uint8_t pb_buf[MAX_PAYLOAD_SIZE];
   pb_ostream_t stream = pb_ostream_from_buffer(pb_buf, sizeof(pb_buf));
 
   if (!pb_encode(&stream, alox_UartMessage_fields, msg)) {
+    ESP_LOGE(TAG, "pb_encode failed type=%u (%s)", (unsigned)msg->type,
+             PB_GET_ERROR(&stream));
     return ESP_FAIL;
   }
 
   uint8_t payload[MAX_PAYLOAD_SIZE];
   if (stream.bytes_written + 1 > sizeof(payload)) {
+    ESP_LOGE(TAG, "payload too large type=%u need=%u max=%u",
+             (unsigned)msg->type, (unsigned)(stream.bytes_written + 1),
+             (unsigned)sizeof(payload));
     return ESP_ERR_NO_MEM;
   }