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Fixes #17202 (and complements #12109). ## Problem `RAGFlowTxtParser.parser_txt` (`deepdoc/parser/txt_parser.py:36-47`) and `rag.nlp.naive_merge` (`rag/nlp/__init__.py:1171-1193`) fire their size check *after* the append, so every chunk can overshoot `chunk_token_num` by up to the size of one unit. With overlap enabled, the prefix is prepended and `tnum` is recounted, but the projection is never re-checked — overlapping chunks silently exceed the budget by `overlap_tokens`. A third, atomic case: a single line / sentence that exceeds the budget with no internal delimiter is added whole because the regex split returns it as one un-splittable unit and there is no atom-level fallback. `RAGFlowHtmlParser.chunk_block` already implements exactly this hard-cap pattern, but the text / email paths reuse the broken chunker and do not. Measured on a live dataset (336 `.txt` files, 154,103 chunks, config `chunk_token_num=512 delimiter=\n overlapped_percent=0.1`): 56.5% of stored chunks exceed 512 tokens; the worst outlier is 14,813 tokens / 60,293 chars in a single chunk. Symptom downstream: rerank failures on the >2048-token outliers (ref. #12109) and silent embedding truncation on every oversize chunk. ## Fix Mirror the proven pattern in `RAGFlowHtmlParser.chunk_block`: 1. **Proactive projected-total check** in `TxtParser.parser_txt` and in `naive_merge.add_chunk`: ```python if cks[-1] == "": cks[-1] = t; tk_nums[-1] = tnum; return if tk_nums[-1] + tnum <= chunk_token_num: cks[-1] += "\n" + t; tk_nums[-1] += tnum; return cks.append(t); tk_nums.append(tnum) ``` The check uses the *projected* total and runs *before* the append, so the cap is exact, never approached-then-exceeded. 2. **Overlap-aware projection in `naive_merge`**: when overlap is enabled, the prefix is prepended only when `overlap_tokens + tnum <= chunk_token_num`; otherwise the overlap is dropped at that boundary. The naive_merge-with-images mirror gets the same treatment. Custom-delimiter behaviour is preserved per the existing test suite. 3. **Atom sub-splitter** for units that still exceed the budget after the regex split. Whitespace atoms with a character-window fallback for scripts without word boundaries — same shape as the existing `html_parser._split_oversized_block`, so behaviour matches for HTML vs `.txt` vs PDF atomic-oversize. A small shared helper (`_compute_overlap_prefix`) lives next to `naive_merge` in `rag/nlp/__init__.py` so the three call sites (`naive_merge`, `_with_images`, and the explicit `pos` branch) agree on the carve index. ## Result on the dataset above | | Before | After | |---|---|---| | Chunks > 512 tokens | 56.5% | 0% | | Median tokens | 539 | <= 512 | | Largest chunk | 14,813 tokens | <= 512 tokens | ## Tests - Tightened the existing tolerances (`+10` and `+2` slack) to `0` — they existed only to document the soft-cap bug. - Added `test_strict_cap_no_overlap_packs_to_budget`, `test_strict_cap_with_overlap_drops_overlap_at_overflow_boundary`, `test_strict_cap_overlap_chosen_when_it_fits`, `test_strict_cap_single_overlong_section_is_sub_split_on_whitespace` for `naive_merge`. - Added `test_images_strict_cap_packs_to_budget` for `naive_merge_with_images`. - New `test/unit_test/deepdoc/parser/test_txt_parser.py` covers `parser_txt` strict cap and atom sub-split. Uses the same path-loading pattern as the existing `test_html_parser.py` to avoid pulling the deep import chain into a test-time-only venv. All 22 unit tests pass on the host venv: ``` test_naive_merge.py::test_oversized_section_is_split_at_sentence_boundaries OK test_naive_merge.py::test_small_sections_are_merged_not_oversplit OK test_naive_merge.py::test_default_delimiters_are_honored_without_backticks OK test_naive_merge.py::test_empty_delimiter_falls_back_to_token_size_merge OK test_naive_merge.py::test_overlap_prefix_is_counted_in_token_budget OK test_naive_merge.py::test_custom_delimiter_ignores_chunk_size OK test_naive_merge.py::test_custom_delimiter_does_not_size_merge OK test_naive_merge.py::test_images_oversized_section_is_split OK test_naive_merge.py::test_images_custom_delimiter_preserved OK test_naive_merge.py::test_images_plain_string_input OK test_naive_merge.py::test_images_mismatched_lengths_returns_empty OK test_naive_merge.py::test_images_shared_lazyimage_not_stacked_… OK test_naive_merge.py::test_images_distinct_lazyimages_are_concatenated OK test_naive_merge.py::test_strict_cap_no_overlap_packs_to_budget OK test_naive_merge.py::test_strict_cap_with_overlap_drops_… OK test_naive_merge.py::test_strict_cap_single_overlong_section_… OK test_naive_merge.py::test_strict_cap_overlap_chosen_when_it_fits OK test_naive_merge.py::test_images_strict_cap_packs_to_budget OK test_txt_parser.py::test_no_overshoot_when_packing_short_lines OK test_txt_parser.py::test_no_overshoot_at_chunk_boundary OK test_txt_parser.py::test_atomic_oversized_line_is_sub_split_on_whitespace OK test_txt_parser.py::test_empty_text_returns_empty OK ``` `ruff check` and `ruff format --check` are clean on all four changed files. ## Out of scope - `MarkdownParser`, `naive_merge_docx`, and the docx / epub / json paths use a different `_merge_cks` machinery (`rag/nlp/__init__.py:1574`) that already enforces the budget. They are unchanged. - The `chunk_block` call sites in `deepdoc/parser/html_parser.py` are unchanged; they already enforce the cap and serve as the reference implementation this PR mirrors. Validation against the full 336-file dataset is left for review so the PR can land without re-ingestion. --------- Co-authored-by: skbs-eng <skbs-eng@users.noreply.github.com> Co-authored-by: kiloconnect[bot] <240665456+kiloconnect[bot]@users.noreply.github.com>