I don't know php very well but here is how you can do it with approximative syntax
$total_length = 0;
$words = $whole_sentense->split(' ')
$word_index = 0
$final_sentense = ''
while($total_length + strlen($words[$word_index]) < 140)
{
$final_sentense .= words[$word_index]
$total_length += strlen($words[$word_index]
$word_index++
}
return ($final_sentense)