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My intention was to collect logs, observe process statuses, etc. and report to the github issue once it reared its head again, but I significantly increased the DHCP lease time in OPNsense and it hasn't happened again (knock on wood).  For reference, I've set the "default lease time" to 604,800 seconds (7 days) and the "maximum lease time" to 1,814,400 seconds (21 days).  These settings are acceptable for me on my home LAN, but your mileage may vary.  I'm pretty sure I had the default OPNsense values for both of those settings previously.

After running just fine for almost two months now, I think that config change fixed it for me.  So if there is a bug in the hostname registration script, it might be triggered by a relatively short lease time and a subsequent lease expiration.

If it comes up again or I find more information, I will report back.

This sounds like the same issue: https://github.com/opnsense/core/issues/7376

and possibly this: https://github.com/opnsense/core/issues/6982

Also, apparently the registered leases should have entries in the

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/var/unbound/dhcpleases.conf file, so I will check that next time the issue occurs.

I wish that I had an answer for you, but I'm experiencing the same issue and I have virtually identical settings in unbound.  I'm also using the ISC DHCP server and having unbound register those leases for DNS lookups.  It seems to work fine for some amount of time -- I haven't seen a pattern exactly, but seemingly on the order of at least days -- after a reboot or a restart of the unbound service.

I guess my next step will be to enable some more verbose logging in unbound to see if I can get any more information that way.  I'm on a fully updated opnsense installation of 24.7.8.

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Type opnsense
Version 24.7.8
Architecture amd64
Commit 9a689f238
Mirror https://pkg.opnsense.org/FreeBSD:14:amd64/24.7