SpeakerDesignProposal

HomeTheatreSpeakers
AlisonPittsley
2012
1

Table of Contents
Design Goals ....................................................................................................................... 2
Box Size Requirements ...................................................................................................... 2
SPL ...................................................................................................................................... 3
Power Requirements.......................................................................................................... 4
Frequency Response .......................................................................................................... 5
Woofers ............................................................................................................................... 6
Tweeters ............................................................................................................................ 11
Crossover .......................................................................................................................... 13
Box Shape & Materials.................................................................................................... 14
Cost.................................................................................................................................... 16
Bibliography ..................................................................................................................... 17

2
Design Goals
This system consists of a stereo pair that will mainly be used for television or film sound
reproduction, but may occasionally be used for music reproduction as well. Enjoyment of the
listening experience, rather than critical listening, is more valuable in this design. I usually listen
at fairly low SPL levels, but I also want these speakers to be close to THX standards for sound
reproduction. Ideally, these speakers would have low power requirements and the frequency
response would cover almost all of the audible range, but certain sacrifices are acceptable to keep
the design around $500 or less. Box size is flexible, but it must be big enough to be a floor
standing speaker. Achieving good low frequency response is more important than high SPL, but
both are desired if possible. Since box size is flexible, cost is the most limiting factor for this
design.
Box Size Requirements
The size specifications for these speakers are relatively flexible since they will be placed on
either side of a television that has open space around it. This home theatre setup will be fairly
permanent so mobility is not a large factor. The preferable box size is smaller than 4 tall by 1.5
wide by 2.5 deep, but these are arbitrary measurements assuming that these will be floor-
standing speakers flanking the television. The speakers will need to have the correct size and
aiming to cover the listening area in a 12 by 16 by 8 room with an average listening height of
3.5 feet. A drawing and approximate values of the listening area are shown below. The walls of
this room are relatively absorptive, so off axis response will not have a huge impact at the
listening area; this means than that on axis response is paramount, and off axis response will not
have much impact on driver choice.

Figure 1: Approximate Listening Area
3


Ear Height Max 5
Ear Height Min 3 (sitting in a chair)
Ear Height Avg. 3.5 (sitting on a 3 high bed)
Ideal Ear Distance From Speakers 7
Room dimensions 14 wide by 20 long by 8 high
Table 1: Approximate Listening Room Dimensions and Positions
SPL
My listening levels are generally much lower than average, around 48 dBA if the noise floor is
low enough. Considering that the noise floor in the intended space for these speakers is higher
than the room I based my preferences on, the average listening level will probably be closer to 60
or 70 dBA. It is also important to consider that I will not be the only one listening to these
speakers, so a more universal standard of SPL capabilities is beneficial. Each speaker in THX
systems are calibrated to a reference level of 85 SPL with a C-weighted level meter, and have a
maximum, undistorted, level of 105 SPL.
1
Having speakers that are capable of THX standards is
ideal, but lower SPL output is acceptable if necessary. Taking my listening preferences into
mind, maximum SPL as low as 85 dBA would be acceptable. With these two values, 85 dBC and
90 dBA, and taking crest factor into account these speakers would have to be able to produce a
maximum of 105 dBC and 110 dBA, respectively.
Room
Level
Comfortably low
listening level
Mixing
Level
Rocking out to a really
good song level
Beginning of
discomfort
40 dBA 48 dBA 60 dBA 73 dBA 90 dBA
Table 2: My SPL preferences based on levels taken in Walker 212
2

1TomlinsonHolman,SoundforFilmandTelevision,(FocalPress,1997),208-209.
2AlisonPittsley,experiment,(SPLPreferences,MichiganTechnologicalUniversity,
MichiganJanuary20,2012).
4
Power Requirements
Ideally, power requirements would remain low, with driver sensitivities 85 dB or above. Given
that the listening area is about 2 meters away from each speaker, 1 watt of power would be
enough to deliver the average listening SPL; higher sensitivities would easily allow smaller
amplifiers to produce maximum SPLs over 100 dBA. Having high driver sensitivity is a very
important since many home theater receivers do not provide more than 100 W per channel.
Assuming a maximum of 100 W, 20 dBW is the most that could be gained by using more power
so a driver with the sensitivity of 85 dB would have a maximum of 105 dB after considering the
crest factor. To reach the maximum of 105 dBC for a THX system, the sensitivity of the drivers
would have to be 105 dB or above; considering sensitivities above approximately 92 dB are less
common and more expensive, a good balance of power capabilities and cost must be found for
each driver.

___ Watts (W) to deliver ___ SPL (dBA) at ___ Meters (M) dBW
1 79 2 0
2 82 2 3
4 85 2 6
8 88 2 9
16 91 2 12
32 94 2 15
64 97 2 18
128 100 2 21
256 103 2 24
512 106 2 27
Table 3: Example power requirement chart, driver sensitivity = 85 dB 1W/1m
___ Watts (W) to deliver ___ SPL
(dBA)
at ___ Meters (M) dBW
1 84 2 0
2 87 2 3
4 90 2 6
8 93 2 9
16 96 2 12
32 99 2 15
64 102 2 18
128 105 2 21
Table 4: Example power requirement chart, driver sensitivity=90 dB 1W/1m
3

3ChristopherPlummer,lecture,(courseonTransducerTheory,MichiganTechnological
University,MichiganJanuary11,2012).
5
Frequency Response
Given that this system will be used mainly for television or films, some might think that the low
frequency limit could be high because vocal frequencies wouldnt be affected until around 300
Hz, the vocal frequency range for humans being about 300 Hz to 3.5 kHz.
4
Though dialogue is
usually considered, on the surface, to be the driving force in TV and films, there is so much more
sound involved in communicating stories, much of it outside the vocal range. Knowing this, but
not knowing how much low frequency usage is common in film mixing, I used THX standards
for an idea of the required frequency response for films and TV. Speakers in THX systems are
calibrated to the X-curve, which begins to roll off around 50 Hz and is about 4 dB down around
25 Hz.
5



Figure 2: X Curve
5


In addition to finding the THX standards, I also did an experiment to find my own low frequency
extension preferences while listening to music. For this experiment I loaded four songs that
represent the kind of music I like to listen to into Logic Pro and put a high pass filter on all of
them. Playing each song and my preferred listening level, I swept the filter higher until I noticed
significant change in the quality of the music. Doing this I found the frequencies where I
thought that low frequency loss was acceptable, and the point at which I thought the loss was not
acceptable (results of this experiment are shown on the next page). Using this information, and
keeping the THX standards in mind, the highest low frequency limit that could be considered is
around 75 Hz, with 43 Hz being the middle ground, and 20 Hz being ideal.

4KenEllis,SoundandLightSALTManual,Lastmodified0519,2001,
http://www.kodachrome/salt/sunderst.htm.

5BrianFlorian,LearningfromHistory:CimemaSoundandEQCurves.Lastmodified06,
2002.AccessedJanuary21,2012.http://www.hometheatrehifi.com/volume_9_2/feature-
article-curves-6-2002.html.
6


Song Title
(Artist)
Maximum loss
(Hz)
Acceptable loss
(Hz)
Thunderstruck
(AC/DC)
81 49
Circle the Drain
(Katy Perry)
63 43
Juke Box Hero
(Foreigner)
87 49
The Luckiest
(Ben Folds)
142 112
Table 5: My low frequency extension preferences
6

Woofers
To begin the woofer selection process I searched for woofers in my price range that had large
frequency ranges and high sensitivities. With these parameters, I came up with the following list
to compare.
Woofer Cost sen.
power
(W)
Max SPL
(dB) Q_ts
F_s
(Hz)
Box Volume
V_b (ft^3)
f_3
(Hz)
Seas CA18RLY $71.55 88 80 107 0.45 40 1.187713006 43.312
Aura
NS6-255-8A $11.50 91 50 108 0.55 55 0.838113058 53.9825
Seas CA12RCY $66.40 86 60 103.5 0.31 57 0.084420221 106.7268
Peerless
HDS Nomex $76.67 89.7 NA 0.38 30 1.880061394 40.368
Peerless
HDS 4" GF Cone $38.33 85.9 30 100.4 0.58 89 0.175989137 79.032
Peerless HDS
PPB 4" Midwoofer $37.23 87 NA 0.54 77.6 0.183771032 71.974
Peerless HDS
5.25" GF Cone $47.30 87 30 101.5 0.49 66 0.329939471 65.8878
Peerless HDS
5.25" Alu Cone $53.67 86.1 30 100.6 0.65 72 0.524224879 60.4944
Peerless HDS PPB
5.25" Midwoofer $43.42 88.3 NA 0.41 56.1 0.337695505 67.83051
Peerless SDS
5.25" Midwoofer $19.14 87 NA 0.54 62.4 0.563564499 57.876
Seas L15RLY/P $78.25 86 80 105 0.35 44 0.26612409 67.3772
W5-1685 $65.70 86 45 103 0.46 50 0.525404181 52.925
Dayton RS225-8 $57.42 86.2 80 105.2 0.36 27.6 1.461003082 40.38432
Table 6: Woofer Spec Spreadsheet

6AlisonPittsley,experiment,(LowFrequencyExtensionPreferences,Michigan
TechnologicalUniversity,MichiganJanuary20,2012).
7
Using Win Speakers, I modeled the system frequency response of all these drivers assuming a
SBB_4 alignment (box volume and f_3 shown in above table). From these models I easily chose
five drivers to examine more closely. They were:
Seas CA18RLY
Aura NS6-255-8A
Seas L15RLY/P
TB W5-1685
Dayton RS225-8
From this point I closely examined frequency response of the drivers and of the system. The
qualities I took into account were, in order:
1. Lowest extending/flattest system response
2. Flattest driver response
3. Highest driver response (as least 3000Hz for crossover at 2000Hz)
4. High sensitivity (All drivers meet minimum sensitivity requirement)

Figure 3: W5-1685 Frequency Response Figure 4: Seas L15RLY/P Frequency Response














Figure 5: Seas CA18RLY Frequency Response


Frequency [Hz]
L15RLY/P
H1141
L15RLY/P is a 15 cm (5) cone driver, developed for use as a long throw
high delity woofer or woofer/midrange unit.
Stiff, yet light aluminium cone and low loss rubber surround show no sign of the
familiar 500-1500 Hz cone edge resonance and distortion associated with soft cones.
Large magnet system , together with very long, and light weight
copper clad aluminium voice coil allow for extreme coil excursion with low
distortion and good transient response.
Extremely stiff and stable injection moulded metal basket, keeps the critical compo-
nents in perfect alignment. Large windows in the basket both above and below the
spider reduce sound reection, air ow noise and
cavity resonances to a minimum.
The frequency responses above show measured free eld sound pressure in 0, 30, and 60 degrees angle using a 7L closed box. Input
2.83 VRMS, microphone distance 0.5m, normalized to SPL 1m.The dotted line is a calculated response in innite bafe
based on the parameters given for this specic driver. The impedance is measured in free air without bafe using a 2V
sine signal.
S
P
L

[
d
B
]
I
m
p
e
d
a
n
c
e

[
o
h
m
]
W15-411 Jul 2007-1 *IEC 268-5
SEAS reserves the right to change technical data
10 100 1 000 10 000
100
95
90
85
80
75
70
65
60
55
50
50
40
30
20
10
0
Nominal Impedance 8 Ohms Voice Coil Resistance 5.5 Ohms
Recommended Frequency Range 45 - 3000 Hz Voice Coil Inductance 0.84 mH
Short Term Power Handling * 200 W Force Factor 5.7 N/A
Long Term Power Handling * 80 W Free Air Resonance 44 Hz
Characteristic Sensitivity (2,83V, 1m) 86 dB Moving Mass 8.1 g
Voice Coil Diameter 26 mm Air Load Mass In IEC Bafe 0.38 g
Voice Coil Height 16 mm Suspension Compliance 1.6 mm/N
Air Gap Height 6 mm Suspension Mechanical Resistance 1.12 Ns/m
Linear Coil Travel (p-p) 10 mm Effective Piston Area 75 cm
2
Maximum Coil Travel (p-p) 20 mm VAS 12 Litres
Magnetic Gap Flux Density 1.1 T QMS 2.10
Magnet Weight 0.42 kg QES 0.43
Total Weight 1.28 kg QTS 0.35
RoHS compliant product www.seas.no
W5-1685 SERIES WF
DIAPHRAGM MTL Paper
SURROUND MTL Rubber
NOMINAL IMPEDANCE 4 W
DCR IMPEDANCE 3.6 W
SENSITIVITY 1W/1M 86 dB
FREQUENCY RESPONSE 50Hz-10 K Hz
FREE AIR RESONANCE 50 Hz
VOICE COIL DIAMETER 38.5 mm
AIR GAP HEIGHT 8.3 mm
RATED POWER INPUT 45 W
MAXIMUM POWER INPUT 90 W
FORCE FACTOR, BL 4.72TM
MAGNET WEIGHT ( 33.1 oz) 938g
MOVING MASS 10.98 g
FERROFLUID ENHANCED No
-1
SUSPENSION COMPLIANCE 1017m MN
2
EFFECTIVE PISTON AREA M
Levc 0.042 mH
Zo 27 ohm
Xmax 6.1 mm
Vas 12.76 Litr
Qts 0.46
Qms 3.33
Qes 0.53
VOICE: 886.2.26570282 FAX: 886.2.26580166
E-MAIL:[email protected]
5 MIDBASS
0.0094
l HUGE FERRITE MAGNET, UNDER HUNG MOTOR DESIGN
l SHORT RING ON POLE PIECE, VC = 38mm
l VERY LOW AND DISTORTION
l LONG THROW, HIGH POWER LOADING, Xmax = 6mm
l NATURALLY HIGH FREQUENCY ROLL OFF, GOOD FOR
CROSSOVER DESIGN
nd rd
2 3
CA18RLY
H1217
CA18RLY is a 6.5" High Fidelity cone driver. developed Ior use as a high
quality wooIer or wooIer/midrange unit.
The classical coated paper cone gives a smooth extended Irequency response
with a controlled roll oII.
A high temperature. light weight. CCAW voice coil wound on an aluminium
voice coil Iormer gives a high power handling capacity. The extremely stiII
and stable iniection moulded metal basket. keeps the critical components in
perIect alignment. Large windows in the basket both above and below the
spider reduce sound reIlection. air Ilow noise and cavity resonance to a
minimum.The large magnet system provides high eIIiciency and low Q.
WOOFER
W18-101
NOTES
NOV 03
!!
NOMINAL IMPEDANCE
RECOMMENDED FREQUENCY RANGE
SHORT TERM MAXIMUM POWER *
LONG TERM MAXIMUM POWER *


VOICE COIL HEIGHT
AIR GAP HEIGHT
LINEAR COIL TRAVEL ( p-p )
MAXIMUM COIL TRAVEL ( p-p)
MAGNETIC GAP FLUX DENSITY
MAGNET WEIGHT
TOTAL WEIGHT
W
W
mm
mm
mm
mm
mm
T
Kg
Kg
VOICE COIL RESISTANCE
FORCE FACTOR
FREE AIR RESONANCE
AIR LOAD MASS IN IEC BAFFLE
SUSPENSION COMPLIANCE
SUSPENSION MECHANICAL RESISTANCE
EFFECTIVE PISTON AREA
VAS
QMS
QES
QTS
Ns/m
mm/N
g
g
Hz
N/A
mH
CHARACTERISTIC SENSITIVITY (1W.1m)
Litres
Hz
Ohms
VOICE COIL DIAMETER
dB SPL
Ohms
MOVING MASS
sq.cm
VOICE COIL INDUCTANCE (EQUIVALENT)
The frequency responses below show measured free field sound pressure in 0. 30. and 60 degrees angle using a
closed box of 12 l net. volume. Input 2.83 Volts RMS. microphone distance 0.5m. normalized to 1m.
The solid line below 500 Hz is a calculated response for an infinite baffle based on the parameters given for this
specific driver. The impedance is measured in free air without baffle.
8
35-2500
250
80
88.0
26
16
6.0
10.0
20
1.25
0.42
1.41
5.9
0.70
5.6
40
11.45
0.86
1.3
1.59
130
30.0
1.94
0.58
0.45
* IEC 268-5
OF NORWAY
8














Figure 6: Dayton RS225-8 Frequency Response










Figure 7: Aura NS6 Frequency Response

Figure 8: W5-1685 SBB_4 Response Figure 9: Seas L15RLY/P SBB_4 Response


Last Revised: 9/16/2010
RS225-8
R
S
2
2
5
-
8
8" Reference Woofer
8
"

R
e
f
e
r
e
n
c
e

W
o
o
f
e
r
8
6.34
0.83
27.6
1.44
0.48
0.36
33.8
0.99
211.2
147.9
8.8
61.8
7.0
38.5
86.2
80
28 -
2,200
Lightweight black anodized
aluminum cone
Attractive 6-hole cast frame
Advanced low distortion
motor design
Solid aluminum phase plug
Rubber surround
50
45
40
35
30
25
20
15
10
5
0
180
90
0 deg
-90
-180
1 2 5 10 20 50 100 200 500 1kHz 2k 5k 10k 20k
Algo Sound, Inc.
2335 Alaska Ave., El Segundo, CA 90245 310.643.5300 310.643.9463 fax
www.aurasound.com
TM TM
TM
Model NS6-255-8A
6 Loudspeaker
High Sensitivity
Compact - Light Weight
NO Stray Magnetic Fields
Nominal Diameter () . . . . . . . . . . . 6 inches (156.4 mm)
Nominal Impedance (Z) . . . . . . . . . . 8 Ohms
Sensitivity, 1W/1m (E) . . . . . . . . . . . 91 dB
Power Capacity, RMS (Pe) . . . . . . . . 50 W
Power Capacity, Peak . . . . . . . . . . . 100 W
Frequency Range (-10dB) . . . . . . . . Fo - 5.5 kHz
Minimum Impedance . . . . . . . . . . . . 8 Ohms
Voice Coil Diameter () . . . . . . . . . . 25.5 mm
Voice Coil Winding Length (h) . . . . . 11.3 mm
Voice Coil Number of Layers (n) . . . . 2
Voice Coil Former Material . . . . . . . . Kapton
Voice Coil Wire Composition . . . . . . Copper
Motor Reference . . . . . . . . . . . . . . . N255-C08-127C
Magnetic Material . . . . . . . . . . . . . . Neodymium radial
Stray Flux Shielding . . . . . . . . . . . . . Inherent
Magnetic Gap Depth (He) . . . . . . . . 12.7 mm
Cone Material . . . . . . . . . . . . . . . . . Paper
Surround Material . . . . . . . . . . . . . . Foam
Polarity, Outward Motion . . . . . . . . . Po s i t i ve voltage on (+) tab
Net Weight . . . . . . . . . . . . . . . . . . . . 0.484 kg
Thiele / Small Parameters
Resonant Frequency (Fo) - Fs . . . . . 55 Hertz
Voice Coil DC Resistance - Re . . . . . 6 Ohms
Total Q - Qts . . . . . . . . . . . . . . . . . . 0.55
Mechanical Q - Qms . . . . . . . . . . . . 10.8
Electrical Q - Qes . . . . . . . . . . . . . . 0.58
Equivalent Volume of Air - Vas . . . . . 16.48 L
Radiating Piston Area - Sd . . . . . . . . 126.0 cm
2
Electrical / Mechanical Parameters
Flux Density x Length - BL . . . . . . . . 6.10 Tesla-meters
Compliance - Cms . . . . . . . . . . . . . . 900 m/N
Total Mass - Mms . . . . . . . . . . . . . . 9.30 grams
Impedance
Frequency Response (1W, 1m)
Distortion (1W, 1m)
TM
4/2/02
20 50 100Hz 200 500 1k 2k Mag
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0 dB
2
4
6
8
10
mm
Exc
Linear Exc Limit
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
Pha
0
90
180
270
360
450
ms
Dly
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TA TA TA TA
Driver Parameters Driver Parameters Driver Parameters Driver Parameters Box Parameters Box Parameters Box Parameters Box Parameters
Driver:
Nominal Diameter
Nominal Power
Sensitivity (1W/1m)
Free Air Resonance
Total Q
Electrical Q
Mechanical Q
Equivalent Volume
Nominal Impedance
DC Resistance
Max Thermal Power
Max Linear Excursion
Max Excursion
Voice Coil Diam.
D =
P =
SPL =
f(s) =
Q(ts) =
Q(es) =
Q(ms) =
V(as) =
Z =
R(e) =
P(t) =
X(max) =
X(lim) =
D(vc) =
5
0
86
50
0.46
0.53
3.33
0.445
0
0
45
6.1
0
0
in
Watts
dB SPL
Hz
cu ft
Ohms
Ohms
Watts
mm
mm
mm
Driver Notes:
NOTE: X(max) was estimated based on the nominal driver
diameter.
NOTE: S(D) was estimated based on the nominal driver
diameter.
System Type: 4th Order Vented Box
Box Volume
Closed Box Q
Box Frequency
Min Rec Vent Area
Vent Surface Area
Vent Length
Compliance Ratio
Box Loss Q
V(B) =
Q(tc) =
F(B) =
S(vMin) =
S(v) =
L(v) =
alpha =
Q(B) =
0.5254
0.6251
50
2.25
0
0
0.8469
7
cu ft
Hz
sq in
sq in
in
System Parameters System Parameters System Parameters System Parameters
No. of Drivers
Isobaric Factor
Input Power
SPL Distance
N =
I =
P(in) =
D =
1
1
2
1
System Notes:
(1=normal, 2=iso)
Watts
m
My Company My Company My Company My Company
My Address, line 1
My Address, line 2
My Country My Phone
TB W5-1685 (SBB4)
4th Order Vented Box
System Name:
Designer:
Title:
Rev Date: Rev:
My Name
My Title
20 50 100Hz 200 500 1k 2k Mag
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0 dB
2
4
6
8
10
mm
Exc
Linear Exc Limit
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
Pha
0
90
180
270
360
450
ms
Dly
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TA TA TA TA
Driver Parameters Driver Parameters Driver Parameters Driver Parameters Box Parameters Box Parameters Box Parameters Box Parameters
Driver:
Nominal Diameter
Nominal Power
Sensitivity (1W/1m)
Free Air Resonance
Total Q
Electrical Q
Mechanical Q
Equivalent Volume
Nominal Impedance
DC Resistance
Max Thermal Power
Max Linear Excursion
Max Excursion
Voice Coil Diam.
D =
P =
SPL =
f(s) =
Q(ts) =
Q(es) =
Q(ms) =
V(as) =
Z =
R(e) =
P(t) =
X(max) =
X(lim) =
D(vc) =
5
0
86
44
0.35
0.43
2.1
0.4238
0
0
80
10
0
0
in
Watts
dB SPL
Hz
cu ft
Ohms
Ohms
Watts
mm
mm
mm
Driver Notes:
NOTE: X(max) was estimated based on the nominal driver
diameter.
NOTE: S(D) was estimated based on the nominal driver
diameter.
System Type: 4th Order Vented Box
Box Volume
Closed Box Q
Box Frequency
Min Rec Vent Area
Vent Surface Area
Vent Length
Compliance Ratio
Box Loss Q
V(B) =
Q(tc) =
F(B) =
S(vMin) =
S(v) =
L(v) =
alpha =
Q(B) =
0.2661
0.5635
44
0.823
0
0
1.593
7
cu ft
Hz
sq in
sq in
in
System Parameters System Parameters System Parameters System Parameters
No. of Drivers
Isobaric Factor
Input Power
SPL Distance
N =
I =
P(in) =
D =
1
1
2
1
System Notes:
(1=normal, 2=iso)
Watts
m
My Company My Company My Company My Company
My Address, line 1
My Address, line 2
My Country My Phone
Seas L15RLY/P (SBB4)
4th Order Vented Box
System Name:
Designer:
Title:
Rev Date: Rev:
My Name
My Title
9
Figure 10: Seas CA18RLY SBB_4 Response Figure 11: Dayton RS225-8 SBB_4 Response



Figure 12: Aura NS6 SSB_4 Response
20 50 100Hz 200 500 1k 2k Mag
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0 dB
2
4
6
8
10
mm
Exc
Linear Exc Limit
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
ms
Dly
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TA TA TA TA
Driver Parameters Driver Parameters Driver Parameters Driver Parameters Box Parameters Box Parameters Box Parameters Box Parameters
Driver:
Nominal Diameter
Nominal Power
Sensitivity (1W/1m)
Free Air Resonance
Total Q
Electrical Q
Mechanical Q
Equivalent Volume
Nominal Impedance
DC Resistance
Max Thermal Power
Max Linear Excursion
Max Excursion
Voice Coil Diam.
D =
P =
SPL =
f(s) =
Q(ts) =
Q(es) =
Q(ms) =
V(as) =
Z =
R(e) =
P(t) =
X(max) =
X(lim) =
D(vc) =
6
0
91
55
0.55
0.58
10.8
0.582
0
0
50
3.05
0
0
in
Watts
dB SPL
Hz
cu ft
Ohms
Ohms
Watts
mm
mm
mm
Driver Notes:
NOTE: X(max) was estimated based on the nominal driver
diameter.
NOTE: S(D) was estimated based on the nominal driver
diameter.
System Type: 4th Order Vented Box
Box Volume
Closed Box Q
Box Frequency
Min Rec Vent Area
Vent Surface Area
Vent Length
Compliance Ratio
Box Loss Q
V(B) =
Q(tc) =
F(B) =
S(vMin) =
S(v) =
L(v) =
alpha =
Q(B) =
1.055
0.6851
55
2.06
0
0
0.5515
7
cu ft
Hz
sq in
sq in
in
System Parameters System Parameters System Parameters System Parameters
No. of Drivers
Isobaric Factor
Input Power
SPL Distance
N =
I =
P(in) =
D =
1
1
2
1
System Notes:
(1=normal, 2=iso)
Watts
m
My Company My Company My Company My Company
My Address, line 1
My Address, line 2
My Country My Phone
Aura NS6-255-8A (SC4)
4th Order Vented Box
System Name:
Designer:
Title:
Rev Date: Rev:
My Name
My Title
20 50 100Hz 200 500 1k 2k Mag
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0 dB
2
4
6
8
10
mm
Exc
Linear Exc Limit
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
Pha
0
90
180
270
360
450
ms
Dly
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TA TA TA TA
Driver Parameters Driver Parameters Driver Parameters Driver Parameters Box Parameters Box Parameters Box Parameters Box Parameters
Driver:
Nominal Diameter
Nominal Power
Sensitivity (1W/1m)
Free Air Resonance
Total Q
Electrical Q
Mechanical Q
Equivalent Volume
Nominal Impedance
DC Resistance
Max Thermal Power
Max Linear Excursion
Max Excursion
Voice Coil Diam.
D =
P =
SPL =
f(s) =
Q(ts) =
Q(es) =
Q(ms) =
V(as) =
Z =
R(e) =
P(t) =
X(max) =
X(lim) =
D(vc) =
6.5
0
88
40
0.45
0.58
1.94
1.06
0
0
80
10
0
0
in
Watts
dB SPL
Hz
cu ft
Ohms
Ohms
Watts
mm
mm
mm
Driver Notes:
NOTE: X(max) was estimated based on the nominal driver
diameter.
NOTE: S(D) was estimated based on the nominal driver
diameter.
System Type: 4th Order Vented Box
Box Volume
Closed Box Q
Box Frequency
Min Rec Vent Area
Vent Surface Area
Vent Length
Compliance Ratio
Box Loss Q
V(B) =
Q(tc) =
F(B) =
S(vMin) =
S(v) =
L(v) =
alpha =
Q(B) =
1.188
0.619
40
6.1
0
0
0.8924
7
cu ft
Hz
sq in
sq in
in
System Parameters System Parameters System Parameters System Parameters
No. of Drivers
Isobaric Factor
Input Power
SPL Distance
N =
I =
P(in) =
D =
1
1
2
1
System Notes:
(1=normal, 2=iso)
Watts
m
My Company My Company My Company My Company
My Address, line 1
My Address, line 2
My Country My Phone
Seas CA18RLY (SBB4)
4th Order Vented Box
System Name:
Designer:
Title:
Rev Date: Rev:
My Name
My Title
20 50 100Hz 200 500 1k 2k Mag
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0 dB
2
4
6
8
10
mm
Exc
Linear Exc Limit
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
Pha
0
90
180
270
360
450
ms
Dly
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TA TA TA TA
Driver Parameters Driver Parameters Driver Parameters Driver Parameters Box Parameters Box Parameters Box Parameters Box Parameters
Driver:
Nominal Diameter
Nominal Power
Sensitivity (1W/1m)
Free Air Resonance
Total Q
Electrical Q
Mechanical Q
Equivalent Volume
Nominal Impedance
DC Resistance
Max Thermal Power
Max Linear Excursion
Max Excursion
Voice Coil Diam.
D =
P =
SPL =
f(s) =
Q(ts) =
Q(es) =
Q(ms) =
V(as) =
Z =
R(e) =
P(t) =
X(max) =
X(lim) =
D(vc) =
8
0
86.2
27.6
0.36
0.48
1.44
2.182
0
0
80
7
0
0
in
Watts
dB SPL
Hz
cu ft
Ohms
Ohms
Watts
mm
mm
mm
Driver Notes:
NOTE: X(max) was estimated based on the nominal driver
diameter.
NOTE: S(D) was estimated based on the nominal driver
diameter.
System Type: 4th Order Vented Box
Box Volume
Closed Box Q
Box Frequency
Min Rec Vent Area
Vent Surface Area
Vent Length
Compliance Ratio
Box Loss Q
V(B) =
Q(tc) =
F(B) =
S(vMin) =
S(v) =
L(v) =
alpha =
Q(B) =
1.46
0.5686
27.6
2.9
0
0
1.495
7
cu ft
Hz
sq in
sq in
in
System Parameters System Parameters System Parameters System Parameters
No. of Drivers
Isobaric Factor
Input Power
SPL Distance
N =
I =
P(in) =
D =
1
1
2
1
System Notes:
(1=normal, 2=iso)
Watts
m
My Company My Company My Company My Company
My Address, line 1
My Address, line 2
My Country My Phone
Dayton RS225-8 (SBB4)
4th Order Vented Box
System Name:
Designer:
Title:
Rev Date: Rev:
My Name
My Title
10
From these choices I cut the drivers that had an f_3 above 50Hz. The final two options were the
Aura NS6-255-8A and the Seas CA18RLY; I chose the Aura because it had a higher sensitivity,
a higher frequency extension, and the Seas low frequency response was not superior enough to
outweigh the benefits of the Aura. When choosing drivers I left the prices out of my spreadsheet
so they would not affect my decisions; once I finally looked up the prices, I realized that I had
chosen a driver that was only $11.50 and thought I must have made a mistake. I did; I had
entered 40Hz as the f_B when it was really 55Hz; this factor had been a huge part in my
decision-making process. The correct system response, as seen above in Figure 12, is not nearly
as attractive as the one that was incorrect.

With the correct system response, the Aura is not as attractive as the Seas in terms of low and flat
frequency response, but all the qualities I liked about the Aura initially were still there, so
deciding whether to keep the Aura, or use the Seas, was very difficult. Initially when comparing
the final drivers, I used f_Bs for SSB_4 alignments because it is the best in terms of low tuning
and transient response, with the SC_4 coming just below it in quality.
7
After I realized that I
chose the Auras based on the lower f_B of 40, I noticed that the Auras f_B with the SC_4
alignment is 42Hz. Given that this alignment gave the type of f_B I needed to get a nice system
response and keep the high sensitivity and high frequency extension, I decided to stick with the
Auras. Using the Auras, I experimented with the number of drivers and box volume to see if I
could come up with a better response. With this, I decided to use four woofers in each speaker,
separating the drivers into two spaces, with two drivers in each space.
Figure 13: Aura NS6 SC_4 Response Figure 14: Aura NS6 Double Driver Response

7VanceDickanson,LoudspeakerDesignCookbook,(Peterborough,NewHampshire:Audio
AmateurPress,2006),62.
20 50 100Hz 200 500 1k 2k Mag
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0 dB
2
4
6
8
10
mm
Exc
Linear Exc Limit
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
ms
Dly
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TA TA TA TA
Driver Parameters Driver Parameters Driver Parameters Driver Parameters Box Parameters Box Parameters Box Parameters Box Parameters
Driver:
Nominal Diameter
Nominal Power
Sensitivity (1W/1m)
Free Air Resonance
Total Q
Electrical Q
Mechanical Q
Equivalent Volume
Nominal Impedance
DC Resistance
Max Thermal Power
Max Linear Excursion
Max Excursion
Voice Coil Diam.
D =
P =
SPL =
f(s) =
Q(ts) =
Q(es) =
Q(ms) =
V(as) =
Z =
R(e) =
P(t) =
X(max) =
X(lim) =
D(vc) =
6
0
91
55
0.55
0.58
10.8
0.582
0
0
50
3.05
0
0
in
Watts
dB SPL
Hz
cu ft
Ohms
Ohms
Watts
mm
mm
mm
Driver Notes:
NOTE: X(max) was estimated based on the nominal driver
diameter.
NOTE: S(D) was estimated based on the nominal driver
diameter.
System Type: 4th Order Vented Box
Box Volume
Closed Box Q
Box Frequency
Min Rec Vent Area
Vent Surface Area
Vent Length
Compliance Ratio
Box Loss Q
V(B) =
Q(tc) =
F(B) =
S(vMin) =
S(v) =
L(v) =
alpha =
Q(B) =
3
0.648
42
6.3
0
0
0.388
7
cu ft
Hz
sq in
sq in
in
System Parameters System Parameters System Parameters System Parameters
No. of Drivers
Isobaric Factor
Input Power
SPL Distance
N =
I =
P(in) =
D =
2
1
2
1
System Notes:
(1=normal, 2=iso)
Watts
m
My Company My Company My Company My Company
My Address, line 1
My Address, line 2
My Country My Phone
Aura NS6-255-8A (SC4)
4th Order Vented Box
System Name:
Designer:
Title:
Rev Date: Rev:
My Name
My Title
20 50 100Hz 200 500 1k 2k Mag
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0 dB
2
4
6
8
10
mm
Exc
Linear Exc Limit
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
ms
Dly
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TA TA TA TA
Driver Parameters Driver Parameters Driver Parameters Driver Parameters Box Parameters Box Parameters Box Parameters Box Parameters
Driver:
Nominal Diameter
Nominal Power
Sensitivity (1W/1m)
Free Air Resonance
Total Q
Electrical Q
Mechanical Q
Equivalent Volume
Nominal Impedance
DC Resistance
Max Thermal Power
Max Linear Excursion
Max Excursion
Voice Coil Diam.
D =
P =
SPL =
f(s) =
Q(ts) =
Q(es) =
Q(ms) =
V(as) =
Z =
R(e) =
P(t) =
X(max) =
X(lim) =
D(vc) =
6
0
91
55
0.55
0.58
10.8
0.582
0
0
50
3.05
0
0
in
Watts
dB SPL
Hz
cu ft
Ohms
Ohms
Watts
mm
mm
mm
Driver Notes:
NOTE: X(max) was estimated based on the nominal driver
diameter.
NOTE: S(D) was estimated based on the nominal driver
diameter.
System Type: 4th Order Vented Box
Box Volume
Closed Box Q
Box Frequency
Min Rec Vent Area
Vent Surface Area
Vent Length
Compliance Ratio
Box Loss Q
V(B) =
Q(tc) =
F(B) =
S(vMin) =
S(v) =
L(v) =
alpha =
Q(B) =
3.109
0.5993
42.15
1.58
0
0
0.1872
7
cu ft
Hz
sq in
sq in
in
System Parameters System Parameters System Parameters System Parameters
No. of Drivers
Isobaric Factor
Input Power
SPL Distance
N =
I =
P(in) =
D =
1
1
2
1
System Notes:
(1=normal, 2=iso)
Watts
m
My Company My Company My Company My Company
My Address, line 1
My Address, line 2
My Country My Phone
Aura NS6-255-8A (SC4)
4th Order Vented Box
System Name:
Designer:
Title:
Rev Date: Rev:
My Name
My Title
11
Tweeters
To begin the tweeter selection process I searched for tweeters in my price range that extended
lower than 2000Hz (assuming a crossover at 2000Hz) and with high sensitivities. With these
parameters, I came up with the following list to compare.

Tweeter Cost F_s sensitivity
power
(W)
f_3
(Hz)
impedence
(ohms)
Max SPL
(dB)
Dayton DCS8F-8 $18.00 637.2 89 50 8 106
Seas H1189 $42.40 550 90 90 6 109
Seas H1212 $45.35 550 92 90 6 111
Vifa BC25TG15-04 $17.00 1130 87.8 50 4 104.8
Vifa BC25SC55-04 $19.80 1400 89.3 100 4 109.3
Vifa XT25SC90-04 $27.20 825 89.9 100 4 109.9
Vifa D27TG-06 $31.17 720 87.4 100 6 107.4
Vifa XT25TG30-04 $34.25 436 110 4 NA
Vifa XT19TD00-04 $38.75 763 87.7 120 900 4 108.7
Vifa XT25BG60-04 $40.10 589 91.5 100 900 4 111.5
Fostex FT48D $96.25 93 50 1000 8 110
ScanSpeak D2608/9130 $81.40 700 91.3 80 1500 8 110.3
ScanSpeak D2606/9220 $51.90 850 91.4 100 1000 6 111.4
ScanSpeak D2606/9200 $36.65 1100 91.4 100 900 6 111.4
Fostex FT28D $68.20 90 40 1500 8 106
Audax TW034X0 $72.05 800 93 70 700 8 88.5
Morel CAT 328-104 $90.80 650 90 200 1700 8 223
Morel MDT 32S $80.40 650 90 200 1500 8 223
Dayton DCS8FS-8 $26.75 812.9 89 50 8 106
Dayton RS28A-4 $54.75 592.2 88 100 4 108
Table 7: Tweeter Spec Spreadsheet

12
Looking at the specs for these tweeters I cut the ones with the least flat responses and highest
frequency extensions first, as well as any tweeter with a nominal impedance below 6 ohms, and
ended up with the following to compare more closely:

Fostex FT48D
ScanSpeak D2608/9130
Audax TW034X0

Figure 15: Fostex Frequency Response Figure 16: Audax Frequency Response


















Figure 17: ScanSpeak Frequency Response




13
Of these tweeters, I chose the one that I thought had the best balance between:

1. Low frequency extension
2. Smooth low frequency roll off
3. Flat high frequency extension through 20kHz
4. Off axis response close to on axis response
5. High sensitivity (All drivers meet minimum sensitivity requirement)

With the idea of a first order crossover in mind, it was important to have low frequency
extension with a smooth roll off. Two of the three of the final tweeters had really smooth roll
offs so I had to take flatness of the high frequencies, off axis response, and sensitivity into higher
account for my final selection. I I ended up choosing the ScanSpeak D2608/9130, even though
the off axis response is very inconsistent at high frequencies, because it has flat response on axis
and a high sensitivity; because the room these will be placed is non-reverberant the off axis
response will not have a very big impact on the listening area.
Crossover
A first order crossover is the only conventional crossover whose combined output reconstruct
the input waveform.
8
This is the reason I put such high value on having a woofer and tweeter
that extended above and below 2000 Hz, respectively. With the ScanSpeak D2608/9130 tweeter
and the Aura NS6-255-8A woofer a first order crossover at 2000 Hz makes a smooth roll off of
both the highs and lows, making for a smooth transition between the tweeter and the woofer.
However, a second order crossover gives a much safer drop in dB at the tweeter resonant
frequency and will probably allow the tweeter a longer life than a first order crossover.


Figure 18: Crossover model of ScanSpeak D2608/9130 tweeter and Aura NS6-255-8A woofer

8PhilipNewell,andKeithHolland,LoudspeakersforMusicRecordingandReproduction,
(ElsevierLtd.,2007),132.
-100
-50
0
50
200 2000
R
e
l
a
t
i
v
e

d
B

FrequencyResponse(Hz)
CrossoverModel
Tweeter1storderailter Woofer1storderailter
ZeroedTweeterResonse ZeroedWooferResonse
Tweeter2ndorderailter Woofer2ndorderailter
14
For these reasons, I decided to go with a second order Linkwitz-Riley crossover, which sums to a
flat magnitude.
9
As stated before, in the woofer section, these speakers will have four drivers
split into two sections. This provides an opportunity to extend low frequency response by
compensating for the baffle step loss with a .5 crossover on the low end. Two woofers will cover
the low and mid frequencies, and the other two will only cover low frequencies. This makes the
speakers more consistent on the vertical axis.
10
With the .5 crossover added on the low end, the
final design will be a second order Linkwitz-Riley 2.5 way crossover.

Figure 19: Example 2.5 Way Crossover
11
Figure 20: Example 2.5 Filter Response
Box Shape & Materials
The boxes are intended to be floor standing, approximately 3.5ft tall by 1.5ft deep by 1.5ft wide.
I had originally planned on making rectangular speakers with rounded edges to reduce edge
diffraction, but the effectiveness of this is rather limited.
12
With a rectangular design, the drivers
were to be placed different distances from the edges of the speakers, which makes a big
improvement in the diffraction loss.
13
I opted for the more complex diamond shape because I
like the look, and because the 45-degree angles off the front baffle help to reduce diffraction loss
a great deal more than rounded or chamfered edges. With the symmetrical look of the diamond
shape, I chose to keep the drivers center on the baffle to keep the symmetrical look.

9VanceDickanson,LoudspeakerDesignCookbook,(Peterborough,NewHampshire:Audio
AmateurPress,2006),162.
10ChristopherPlummer,lecture,(courseonTransducerTheory,MichiganTechnological
University,MichiganFeburary,152012).
11PaulSpencer,RedSpadeAudioBlog,"EtudeTLcrossover."Lastmodified0629,2011.
AccessedApril26,2012.http://redspade-audio.blogspot.com/2011/06/etude-tl-
crossover.html.
12LinkwitzLab,Diffractionfrombaffleedges.Lastmodified10/04/2011.Accessed
January29,2012.http://www.linkwitzlab.com/diffraction.htm.
13John L. Murphy, Introduction to Loudspeaker Design, (Andersonville, TN: True Audio,
1998), 71.
Posted by Paul Spencer
keep the efficiency up.
The inductor (L2) provides the low pass, while R2 and capacitor C2 provide
impedance equalisation. This means the inductor sees the driver as having a
constant impedance. C5 is needed only where low cost electro caps are used.
You may notice that the low pass filter is applied at a lower point than the acoustic
crossover point of 3.5k. The acoustic response of the driver is combined with the filter
to give the desired crossover point.
3. Woofer network
The
inductor
(L1) has a
greater
value to
apply a
gentle
first order low pass above 200 Hz. This network essentially provides bafflestep
compensation. It compensates for the loss of efficiency below a point determined by
baffle width. A 2 way design has both drivers reproducing midrange and bass but
uses EQ to allow for bafflestep.
If there is one criticism of this crossover, it would be that the tweeter crossover is a
little high. The result is off axis lobing. Generally, a speaker with a 6.5" mid and 1"
dome with a 105mm face plate should cross around 2.4k to avoid this problem. As a
result, I suggest keeping the vertical spacing as close as you can without looking
cramped. The higher crossover results in greater power handling, but at 3.5k the mid
is starting to beam. At the crossover point the dispersion will rapidly shift since the
tweeter has much wider dispersion. This is always a problem with conventional
speakers such as this, but the high crossover point makes it a little worse.
Return to main TL speaker page
If you already have the JV60, I have some suggestions for upgrades.
Continue to crossover upgrades
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15
The box material needed to be stiff enough so that the speakers will not resonate with the drivers.
To achieve stiffness of the box I decided to use two layers of wood. On the outside, birch
plywood with the highest ply possible to increase rigidity, and on the inside, MDF which is
heavy and will vibrate less in tandem with the driver.
14
The MDF will also be used a brace that
separates the box into two sealed enclosures (besides the ports). Each box will have two tuning
ports, one for each enclosure. These ports will be located on the back diagonal of the boxes so
that the box noise will not be directed at the listening area, nor will it be reflected off the wall
behind it.

Once the boxes are constructed, the unique shape and wood grain will create a nice aesthetic. I
plan to keep this natural look by using natural wood stain, and possibly a clear glossy coat to a
more finished look.


Figure 21: 3D Rendering of Speaker Design

14
PhilipNewell,andKeithHolland,LoudspeakersforMusicRecordingandReproduction,
(ElsevierLtd.,2007),87.
16
Cost
The budget for these speakers is around $500, with limited flexibility for better quality. My
initial thought was that each driver could cost no more than $100, which was one of the limiting
factors when finding drivers to compare. This would have left about $100, which would not have
been enough to cover wood and crossover costs. The low cost of the woofers and tweeters
leaves enough money for wood and crossover materials, in addition to less significant costs like
shipping, glue, and stain.

Quantity Cost Total
Woofer 8 $11.50 $92.00
Tweeter 2 $81.40 $162.80
Baltic Birch
4x8 2 $60.00 $120.00
MDF 4x8 2 $40.00 $80.00
Total: $454.80
Table 8: Current Speaker Budget
17
Bibliography

Custom Car Stereo, "Xover Calculators." Accessed April 26, 2012.
http://ccs.exl.info/calc_cr.html
Dickanson, Vance. Loudspeaker Design Cookbook. Peterborough, New Hampshire: Audio
Amateur Press, 2006.
Ellis, Ken. Sound and Light SALT Manual. Last modified 05 19, 2001.
http://www.kodachrome/salt/sunderst.htm.
Florian, Brian. Learning from History: Cimema Sound and EQ Curves. Last modified 06,
2002. Accessed January 21, 2012. http://www.hometheatrehifi.com/volume_9_2/feature-
article-curves-6-2002.html.
Holman ,Tomlinson. Sound for Film and Television. Focal Press, 1997.
King, Martin J. Simple Sizing of the Components in a Baffle Step Correction Circuit. 2005.
Linkwitz Lab, Diffraction from baffle edges. Last modified 10/04/2011. Accessed January 29,
2012. http://www.linkwitzlab.com/diffraction.htm.
McCarthy, Bob. Sound Systems: Design and Optimization. Burlington, MA: Elsevier Ltd., 2010.
Murphy, John L. Introduction to Loudspeaker Design. Andersonville, TN: True Audio, 1998.
Newell, Philip, and Keith Holland. Loudspeakers for Music Recording and Reproduction.
Elsevier Ltd., 2007.
Pittsley, Alison. Experiment, (Low Frequency Extension Preferences, Michigan Technological
University, Michigan January 20, 2012).
Pittsley, Alison. Experiment, (SPL Preferences, Michigan Technological University, Michigan
January 20, 2012).
Plummer , Christopher. Lecture, (course on Transducer Theory, Michigan Technological
University, Michigan January 11, 2012).
Plummer , Christopher. Lecture, (course on Transducer Theory, Michigan Technological
University, Michigan Feburary, 15 2012).
Spencer, Paul. Red Spade Audio Blog, "Etude TL crossover." Last modified 06 29, 2011.
Accessed April 26, 2012. http://redspade-audio.blogspot.com/2011/06/etude-tl-
crossover.html.