fix(kb): scale kb-ingest timeout default with input size

[asachs01]

Summary

• The flat 600s (KB_INGEST_TIMEOUT_DEFAULT_MS) default in ingestKnowledgeBase ETIMEDOUT on two independent agents' MEMORY.md files (analyst: 476 chunks/97k tokens; adoption: 323 chunks) — both confirmed fixed only by manually setting KB_INGEST_TIMEOUT_MS=1800000. Since MEMORY.md only grows over an agent's lifetime (several fleet agents are already 400-550KB), every long-lived agent eventually hits this wall.
• Scale the default with total input byte size (1.5ms/byte, a deliberately generous rate grounded in the one real data point — a several-hundred-KB file succeeding within the 30min manual override), floored at the existing 600s minimum (no behavior change for small files) and capped at 1h (so a huge/malformed input still fails loud instead of hanging indefinitely).
• KB_INGEST_TIMEOUT_MS still wins outright when explicitly set — this only changes what "default" resolves to.

Closes task_1787849190389_13577787 (cortextos bus list-tasks).

Test plan

• npx tsc --noEmit clean
• npm run build clean
• npx vitest run tests/unit/bus/knowledge-base.test.ts — 14/14 pass (8 existing + 6 new: floor-unchanged-for-small-input, scales-up-for-large-input, capped-at-1h, env-override-still-wins, unreadable-path-skipped-not-fatal, multi-path-sizes-sum)
• Full npx vitest run — only pre-existing unrelated failures (dashboard next/server import errors in this worktree, one known-flaky chokidar watcher test per CLAUDE.md's 2026-07-28 flaky-test note), none touching this file

🤖 Generated with Claude Code

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Summary by CodeRabbit

• Bug Fixes
  • Knowledge-base ingestion timeouts now scale with the total size of input files.
  • Timeouts enforce minimum and maximum limits for more predictable processing.
  • Unreadable inputs no longer prevent timeout calculation.
  • A configurable environment setting can override the calculated timeout.

[coderabbitai]

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📥 Commits

Reviewing files that changed from the base of the PR and between e44bf20 and d618ce3.

📒 Files selected for processing (2)

• src/bus/knowledge-base.ts
• tests/unit/bus/knowledge-base.test.ts

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📝 Walkthrough

Walkthrough

Knowledge-base ingestion now sizes its default timeout from readable input bytes. The timeout remains bounded by a 60-second floor and one-hour cap. KB_INGEST_TIMEOUT_MS overrides the calculation. Unit tests cover scaling, limits, overrides, stat failures, and cumulative inputs.

Changes

Knowledge-base ingest timeout

Layer / File(s)	Summary
Timeout sizing and validation src/bus/knowledge-base.ts, tests/unit/bus/knowledge-base.test.ts	The ingest timeout uses readable input sizes at 1.5 ms per byte, with a 600-second minimum and one-hour maximum. A positive KB_INGEST_TIMEOUT_MS value overrides the calculation. Stat failures do not abort ingestion. Tests cover these cases and cumulative input sizes.

Estimated code review effort: 3 (Moderate) | ~20 minutes

Merge Risk: ⚪ Minimal · up to d618c

Knowledge-base ingestion timeouts now scale with readable input size while preserving bounded defaults and explicit overrides. The change is covered for its intended sizing and failure-handling behavior, with no current merge-blocking risk identified.

🚥 Pre-merge checks | ✅ 4 | ❌ 1

❌ Failed checks (1 warning)

Check name	Status	Explanation	Resolution
Docstring Coverage	⚠️ Warning	Docstring coverage is 50.00% which is insufficient. The required threshold is 80.00%. Docstring coverage is scoped to functions touched by this diff. Analyzed 2 functions across 2 files.	Write docstrings for the functions missing them to satisfy the coverage threshold.

✅ Passed checks (4 passed)

Check name	Status	Explanation
Description Check	✅ Passed	Check skipped - CodeRabbit’s high-level summary is enabled.
Title check	✅ Passed	The title clearly and concisely describes the main change: scaling the default knowledge-base ingest timeout with input size.
Linked Issues check	✅ Passed	Check skipped because no linked issues were found for this pull request.
Out of Scope Changes check	✅ Passed	Check skipped because no linked issues were found for this pull request.

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✨ Finishing Touches 💡 1

📝 Generate docstrings 💡

• Create stacked PR
• Commit on current branch

🧪 Generate unit tests (beta)

• Create PR with unit tests
• Commit unit tests in branch fix/kb-ingest-timeout-scaling

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