feat(tts): map logical pool voices to distinct Piper speakers on Speaches

Until now the Speaches branch sent every request to the single env-configured
model (de_DE-thorsten — a German voice for English radio), so the voice pool
had no audible effect. A server-side registry now resolves the logical voice
ids to disjoint controller/pilot Piper speakers; unknown ids keep the env
fallback and the cache key follows the resolved pair.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

server/api/atc/say.post.ts

@@ -10,6 +10,7 @@ import { TransmissionLog } from "../../models/TransmissionLog";
 import { requireUserSession } from "../../utils/auth";
 import { enforceRateLimit } from "../../utils/rateLimit";
 import { recordUsage } from "../../utils/usage";
+import { resolveSpeachesVoice } from "../../utils/voiceRegistry";
 
 
 function outDir() {
@@ -204,8 +205,18 @@ export default defineEventHandler(async (event) => {
     const useSpeaches = runtimeConfig.useSpeaches;
     const usePiper = !useSpeaches && runtimeConfig.usePiper;
     const provider = resolveTtsProvider(useSpeaches, usePiper);
-    const providerModel = provider === "speaches"
-        ? (runtimeConfig.speechModelId || "speaches-ai/piper-en_US-ryan-low")
+    // Speaches: logical pool voices (alloy, verse, …) resolve to Piper
+    // model+voice pairs; anything unknown keeps the env-configured pair.
+    const speachesFallback = {
+        model: runtimeConfig.speechModelId || "speaches-ai/piper-en_US-ryan-low",
+        voice,
+    };
+    const speachesVoice = provider === "speaches"
+        ? resolveSpeachesVoice(voice, speachesFallback)
+        : null;
+    const ttsVoice = speachesVoice?.voice ?? voice;
+    const providerModel = speachesVoice
+        ? speachesVoice.model
         : provider === "piper"
             ? "piper-local"
             : TTS_MODEL;
@@ -221,7 +232,7 @@ export default defineEventHandler(async (event) => {
         ? buildFlightLabCacheKey({
             normalized,
             level,
-            voice,
+            voice: ttsVoice,
             speed,
             format: fmt,
             provider,
@@ -263,11 +274,11 @@ export default defineEventHandler(async (event) => {
         if (!audioBuffer && useSpeaches) {
             // Speaches (prefer compact: MP3, otherwise FLAC/WAV/PCM)
             const baseUrl = runtimeConfig.speachesBaseUrl || "";
-            const model = runtimeConfig.speechModelId || "speaches-ai/piper-en_US-ryan-low";
+            const model = providerModel;
             if (!baseUrl) {
                 throw new Error("SPEACHES_BASE_URL not set");
             }
-            audioBuffer = await speachesTTS(normalized, voice, model, fmt, baseUrl, speed);
+            audioBuffer = await speachesTTS(normalized, ttsVoice, model, fmt, baseUrl, speed);
             modelUsed = model;
             // Server returns the correct format according to response_format
             actualMime = fmtToMime(fmt);

server/utils/voiceRegistry.test.ts

@@ -0,0 +1,39 @@
+import { describe, it } from 'node:test'
+import assert from 'node:assert/strict'
+import { resolveSpeachesVoice, SPEACHES_VOICE_MAP } from '~~/server/utils/voiceRegistry'
+
+const fallback = { model: 'speaches-ai/piper-de_DE-thorsten-medium', voice: 'de_DE-thorsten-medium' }
+
+describe('resolveSpeachesVoice', () => {
+  it('maps every pool voice to a matching piper model/voice pair', () => {
+    for (const [logical, mapped] of Object.entries(SPEACHES_VOICE_MAP)) {
+      const result = resolveSpeachesVoice(logical, fallback)
+      assert.equal(result.voice, mapped.voice)
+      assert.equal(result.model, `speaches-ai/piper-${mapped.voice}`)
+    }
+  })
+
+  it('maps the default controller voice to an English speaker', () => {
+    const result = resolveSpeachesVoice('alloy', fallback)
+    assert.match(result.voice, /^en_/)
+  })
+
+  it('is case-insensitive and trims', () => {
+    const result = resolveSpeachesVoice('  Alloy ', fallback)
+    assert.equal(result.voice, SPEACHES_VOICE_MAP.alloy!.voice)
+  })
+
+  it('falls back to the configured pair for unknown ids', () => {
+    assert.deepEqual(resolveSpeachesVoice('somepipervoice', fallback), fallback)
+    assert.deepEqual(resolveSpeachesVoice('', fallback), fallback)
+  })
+
+  it('keeps controller and pilot voices audibly disjoint', () => {
+    const controller = ['alloy', 'echo', 'onyx', 'sage'].map(v => resolveSpeachesVoice(v, fallback).voice)
+    const pilots = ['verse', 'ash', 'ballad', 'coral', 'fable', 'nova', 'shimmer']
+      .map(v => resolveSpeachesVoice(v, fallback).voice)
+    for (const voice of controller) {
+      assert.equal(pilots.includes(voice), false, `${voice} used for both controller and pilot`)
+    }
+  })
+})

server/utils/voiceRegistry.ts

@@ -0,0 +1,40 @@
+/**
+ * Maps the product-wide logical voice ids (shared/utils/voicePool.ts — OpenAI
+ * voice names) to Speaches/Piper model+voice pairs. The client keeps sending
+ * pool names; only the Speaches branch of /api/atc/say resolves them here, so
+ * the same ids work unchanged on the OpenAI provider.
+ *
+ * Speaches auto-downloads missing `speaches-ai/piper-*` models on first use.
+ * Controller voices (alloy/echo/onyx/sage) and pilot voices (verse + the
+ * PILOT_VOICES pool) map to disjoint speakers so traffic never sounds like
+ * the controller talking to itself.
+ */
+
+export type SpeachesVoice = { model: string; voice: string }
+
+const piper = (voice: string): SpeachesVoice => ({
+  model: `speaches-ai/piper-${voice}`,
+  voice,
+})
+
+export const SPEACHES_VOICE_MAP: Record<string, SpeachesVoice> = {
+  // Controller pool (CONTROLLER_VOICES)
+  alloy: piper('en_US-ryan-medium'),
+  echo: piper('en_GB-alan-medium'),
+  onyx: piper('en_US-john-medium'),
+  sage: piper('en_GB-jenny_dioco-medium'),
+  // The user's own readback voice (speakPilotReadback)
+  verse: piper('en_US-lessac-medium'),
+  // Simulated pilot pool (PILOT_VOICES)
+  ash: piper('en_US-joe-medium'),
+  ballad: piper('en_GB-northern_english_male-medium'),
+  coral: piper('en_US-amy-medium'),
+  fable: piper('en_US-danny-low'),
+  nova: piper('en_US-hfc_female-medium'),
+  shimmer: piper('en_US-kristin-medium'),
+}
+
+export function resolveSpeachesVoice(logical: string, fallback: SpeachesVoice): SpeachesVoice {
+  const key = (logical || '').trim().toLowerCase()
+  return SPEACHES_VOICE_MAP[key] ?? fallback
+}