QUOTE (chelgrian @ Jun 2 2009, 16:49)

Size has very little to do with efficiency or harmonic distortion. In fact it is far more difficult to make large drivers due to the trade off between rigidity of the cone and mass. If the cone is insufficiently rigid then it will flex as it is moved by the voice coil introducing distortion into the sound. However if the cone is too massive then it will accelerate more slowly in response to the force provided by the voice coil introducing phase errors and other aberrations into the signal.
I'm not buying much of this. Very few speakers have diaphragms that are sufficiently rigid to avoid flexing. Just because a diaphragm flexes doesn't mean that it will necessarily produce excessive nonlinear distoriton.
The irreducable problem with large diaphragms (large SD) is their directivity. Large pistons are directional at high frequencies, and that is that. The circumvention is to have a large diaphragm that breaks up smoothly. That's hard to do.
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Most 'hifi" quality full range drive units don't go beyond about 8" due to these issues.
Hi fidelity full range drive units don't really exist. The ones that are claimed to exist fall have issues with directionality and smoothness of break up.
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The biggest cones used in subs for use with line arrays tend to be of the order of 18". TurboSound used to make a sub with a 24" cone but they discontinued it and reverted to 18" cones.
This is all about costs and benefits. The purpose of a subwoofer driver is to move air. Moving air is dependent on Xmax and SD. Due to geometric limitations, large Xmax and small SD are mutually exclusive. The ready alternative to large SD is simply to use multiple drivers. Tooling costs apply. Large tools cost more money. The cost of tooling is divided by the number of items produced. Right now very large Xmax times SD can be obtained with drivers in the 13 to 18 inch range.
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Also the bigger the enclosure the more difficult it is to design it to be rigid and not to colour the signal via unwanted resonance and other effects.
Cross-bracing and more modern approaches like carbon fiber reinforcement and foamed plastic construction address the resonance problems. In the end concerns with size issues during the final installation and shipping costs come into the discussion.
Furthermore, large drivers don't necessarily demand large enclosures.
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The digital loudspeaker management systems used with large systems provide active crossover and delay per band to increase power handling by removing passive crossover networks from the systems and to compensate for phase errors due to the both placement of drivers and in some cases reaction speed.
You were doing really good up until the "reaction speed" thing.
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Perception of "loudness" is also influenced by the frequency of the signal and distortion. A slightly distorted signal will actually be perceived as being louder than a completely clean signal.
Agreed. That's one reason why some think that vinyl sounds "more dynamic".
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Where the sound energy is concentrated in the spectrum also has an effect, ever noticed how adverts are perceived to be louder than program material? In fact the average energy is the same but the signal has been processed to concentrate the energy into the frequency bands that human ears are most sensitive to.
Also agreed on all points.