voice: one macOS output policy across WAV, beeps, streaming TTS + tests

Addresses review on #62601. Applies a single rule — no sounddevice for
audio OUTPUT on macOS (PortAudio/CoreAudio init triggers a
kTCCServiceMediaLibrary prompt) — consistently at all three output sites:

- play_audio_file: WAV playback (already routed to afplay) now uses the
  shared _sounddevice_output_allowed() helper.
- play_beep: synthesize the tone with numpy only, then on macOS play it
  via a temp WAV through afplay instead of sounddevice.
- stream_tts_to_speaker (tts_tool): on macOS, skip the sounddevice
  OutputStream so playback falls through to the existing tempfile/afplay path.

Audio INPUT (recording) is untouched — it legitimately needs mic permission.

Tests: TestMacOSAudioOutputPolicy (voice_mode) proves WAV + beep routing
does not import sounddevice on Darwin and still uses it off Darwin;
test_tts_macos_output proves streaming TTS skips the OutputStream on Darwin.
Existing test_play_wav_via_sounddevice pinned to non-Darwin for determinism.

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

tests/tools/test_tts_macos_output.py

@@ -0,0 +1,100 @@
+"""macOS output policy for streaming TTS.
+
+On macOS, stream_tts_to_speaker must NOT open a sounddevice OutputStream
+(PortAudio/CoreAudio init triggers a kTCCServiceMediaLibrary prompt). It
+should route audio through the tempfile/afplay fallback instead.
+See PR #62601 / #13291.
+"""
+
+import queue
+import threading
+
+import pytest
+
+
+def _run_stream(monkeypatch, system_name):
+    """Drive stream_tts_to_speaker once with a mock client on *system_name*.
+
+    Returns True if _import_sounddevice was called during the run.
+    """
+    import tools.tts_tool as tts
+
+    monkeypatch.setattr("tools.tts_tool.platform.system", lambda: system_name)
+    monkeypatch.setattr("tools.tts_tool.get_env_value",
+                        lambda name, default=None: "fake-key"
+                        if name == "ELEVENLABS_API_KEY" else default)
+    monkeypatch.setattr("tools.tts_tool._load_tts_config", lambda: {})
+
+    class _FakeTTS:
+        def __init__(self, *a, **k):
+            self.text_to_speech = self
+
+        def convert(self, *a, **k):
+            return iter([])  # no audio chunks needed for setup assertion
+
+    monkeypatch.setattr("tools.tts_tool._import_elevenlabs", lambda: _FakeTTS)
+
+    sd_called = {"hit": False}
+
+    def _spy_import_sd():
+        sd_called["hit"] = True
+        raise AssertionError("sounddevice must not be imported for output on macOS")
+
+    monkeypatch.setattr("tools.tts_tool._import_sounddevice", _spy_import_sd)
+
+    text_queue: queue.Queue = queue.Queue()
+    text_queue.put(None)  # end-of-text sentinel: no sentence spoken
+    stop_event = threading.Event()
+    done_event = threading.Event()
+
+    tts.stream_tts_to_speaker(text_queue, stop_event, done_event)
+    assert done_event.is_set()
+    return sd_called["hit"]
+
+
+def test_streaming_tts_skips_sounddevice_on_macos(monkeypatch):
+    assert _run_stream(monkeypatch, "Darwin") is False
+
+
+def test_streaming_tts_uses_sounddevice_off_macos(monkeypatch):
+    # Off macOS the OutputStream setup runs; _import_sounddevice raising here
+    # is caught by the function's own guard, so the call itself is what we assert.
+    called = _run_stream_offmac(monkeypatch)
+    assert called is True
+
+
+def _run_stream_offmac(monkeypatch):
+    """Like _run_stream but tolerant of the sounddevice import being attempted."""
+    import tools.tts_tool as tts
+
+    monkeypatch.setattr("tools.tts_tool.platform.system", lambda: "Linux")
+    monkeypatch.setattr("tools.tts_tool.get_env_value",
+                        lambda name, default=None: "fake-key"
+                        if name == "ELEVENLABS_API_KEY" else default)
+    monkeypatch.setattr("tools.tts_tool._load_tts_config", lambda: {})
+
+    class _FakeTTS:
+        def __init__(self, *a, **k):
+            self.text_to_speech = self
+
+        def convert(self, *a, **k):
+            return iter([])
+
+    monkeypatch.setattr("tools.tts_tool._import_elevenlabs", lambda: _FakeTTS)
+
+    sd_called = {"hit": False}
+
+    def _spy_import_sd():
+        sd_called["hit"] = True
+        raise OSError("no audio device in test")  # handled by the function's guard
+
+    monkeypatch.setattr("tools.tts_tool._import_sounddevice", _spy_import_sd)
+
+    text_queue: queue.Queue = queue.Queue()
+    text_queue.put(None)
+    stop_event = threading.Event()
+    done_event = threading.Event()
+
+    tts.stream_tts_to_speaker(text_queue, stop_event, done_event)
+    assert done_event.is_set()
+    return sd_called["hit"]

tests/tools/test_voice_mode.py

@@ -1140,6 +1140,10 @@ class TestWhisperHallucinationFilter:
 class TestPlayAudioFile:
     def test_play_wav_via_sounddevice(self, monkeypatch, sample_wav):
         np = pytest.importorskip("numpy")
+        # Pin to a non-macOS platform: on macOS WAV output deliberately skips
+        # sounddevice (see TestMacOSAudioOutputPolicy), so this path is only
+        # exercised off Darwin.
+        monkeypatch.setattr("tools.voice_mode.platform.system", lambda: "Linux")
 
         mock_sd_obj = MagicMock()
         # Simulate stream completing immediately (get_stream().active = False)
@@ -1178,6 +1182,106 @@ class TestPlayAudioFile:
         assert result is False
 
 
+# ============================================================================
+# macOS output policy (no sounddevice for OUTPUT -> avoids TCC prompt)
+# ============================================================================
+
+class TestMacOSAudioOutputPolicy:
+    def test_output_disallowed_on_macos(self, monkeypatch):
+        monkeypatch.setattr("tools.voice_mode.platform.system", lambda: "Darwin")
+        from tools.voice_mode import _sounddevice_output_allowed
+
+        assert _sounddevice_output_allowed() is False
+
+    def test_output_allowed_off_macos(self, monkeypatch):
+        monkeypatch.setattr("tools.voice_mode.platform.system", lambda: "Linux")
+        from tools.voice_mode import _sounddevice_output_allowed
+
+        assert _sounddevice_output_allowed() is True
+
+    def test_play_audio_file_skips_sounddevice_on_macos(self, monkeypatch, sample_wav):
+        """On macOS, WAV playback must not import sounddevice; it routes to afplay."""
+        monkeypatch.setattr("tools.voice_mode.platform.system", lambda: "Darwin")
+
+        def _forbidden_import():
+            raise AssertionError("sounddevice must not be imported for output on macOS")
+
+        monkeypatch.setattr("tools.voice_mode._import_audio", _forbidden_import)
+
+        popen_cmds = []
+
+        class _FakeProc:
+            def wait(self, timeout=None):
+                return 0
+
+            def kill(self):
+                pass
+
+        def _fake_popen(cmd, **kwargs):
+            popen_cmds.append(cmd)
+            return _FakeProc()
+
+        monkeypatch.setattr("shutil.which", lambda exe: f"/usr/bin/{exe}")
+        monkeypatch.setattr("subprocess.Popen", _fake_popen)
+
+        from tools.voice_mode import play_audio_file
+
+        result = play_audio_file(sample_wav)
+
+        assert result is True
+        assert popen_cmds, "expected a system player to be invoked"
+        assert popen_cmds[0][0] == "afplay"
+
+    def test_play_beep_routes_through_afplay_on_macos(self, monkeypatch):
+        """On macOS, beeps synthesize with numpy but play via the tempfile/afplay path."""
+        pytest.importorskip("numpy")
+        monkeypatch.setattr("tools.voice_mode.platform.system", lambda: "Darwin")
+
+        def _forbidden_import():
+            raise AssertionError("sounddevice must not be imported for beeps on macOS")
+
+        monkeypatch.setattr("tools.voice_mode._import_audio", _forbidden_import)
+
+        calls = []
+        monkeypatch.setattr(
+            "tools.voice_mode._play_int16_via_tempfile",
+            lambda audio, sample_rate: calls.append((len(audio), sample_rate)),
+        )
+
+        import tools.voice_mode as vm
+
+        vm.play_beep(frequency=880, count=1)
+
+        assert len(calls) == 1
+        n_samples, sample_rate = calls[0]
+        assert n_samples > 0
+        assert sample_rate == vm.SAMPLE_RATE
+
+    def test_play_beep_uses_sounddevice_off_macos(self, monkeypatch):
+        """Off macOS, beeps go straight through sounddevice."""
+        np = pytest.importorskip("numpy")
+        monkeypatch.setattr("tools.voice_mode.platform.system", lambda: "Linux")
+
+        mock_sd = MagicMock()
+        mock_stream = MagicMock()
+        mock_stream.active = False
+        mock_sd.get_stream.return_value = mock_stream
+        monkeypatch.setattr("tools.voice_mode._import_audio", lambda: (mock_sd, np))
+
+        tempfile_calls = []
+        monkeypatch.setattr(
+            "tools.voice_mode._play_int16_via_tempfile",
+            lambda audio, sample_rate: tempfile_calls.append(True),
+        )
+
+        import tools.voice_mode as vm
+
+        vm.play_beep(frequency=880, count=1)
+
+        mock_sd.play.assert_called_once()
+        assert not tempfile_calls, "off macOS should not use the tempfile/afplay path"
+
+
 # ============================================================================
 # cleanup_temp_recordings
 # ============================================================================

tools/tts_tool.py

@@ -41,6 +41,7 @@ import json
 import logging
 import os
 import queue
+import platform
 import re
 import shlex
 import shutil
@@ -3188,20 +3189,28 @@ def stream_tts_to_speaker(
                 )
             except Exception:
                 stream_max_len = 0
-            try:
-                sd = _import_sounddevice()
-                output_stream = sd.OutputStream(
-                    samplerate=streamer.sample_rate,
-                    channels=streamer.channels,
-                    dtype="int16",
-                )
-                output_stream.start()
-            except (ImportError, OSError) as exc:
-                logger.debug("sounddevice not available, streamer→tempfile: %s", exc)
-                output_stream = None
-            except Exception as exc:
-                logger.warning("sounddevice OutputStream failed: %s", exc)
+            # On macOS, skip the sounddevice OutputStream entirely: PortAudio/
+            # CoreAudio init triggers a kTCCServiceMediaLibrary permission
+            # prompt even though output needs no media-library access. Leaving
+            # output_stream=None routes each sentence through the tempfile
+            # -> play_audio_file -> afplay path. See PR #62601 / #13291.
+            if platform.system() == "Darwin":
                 output_stream = None
+            else:
+                try:
+                    sd = _import_sounddevice()
+                    output_stream = sd.OutputStream(
+                        samplerate=streamer.sample_rate,
+                        channels=streamer.channels,
+                        dtype="int16",
+                    )
+                    output_stream.start()
+                except (ImportError, OSError) as exc:
+                    logger.debug("sounddevice not available, streamer→tempfile: %s", exc)
+                    output_stream = None
+                except Exception as exc:
+                    logger.warning("sounddevice OutputStream failed: %s", exc)
+                    output_stream = None
 
         chunker = SentenceChunker()
         long_flush_len = 100

tools/voice_mode.py

@@ -42,6 +42,55 @@ def _import_audio():
     return sd, np
 
 
+def _import_numpy():
+    """Lazy-import numpy only (no sounddevice).  Returns the module.
+
+    Used where we need to synthesize/convert audio samples but must NOT
+    import sounddevice — see _sounddevice_output_allowed.
+    """
+    import numpy as np
+    return np
+
+
+def _sounddevice_output_allowed() -> bool:
+    """Whether sounddevice may be used for audio OUTPUT.
+
+    Returns False on macOS: importing/initializing sounddevice
+    (PortAudio/CoreAudio) for output triggers a kTCCServiceMediaLibrary
+    permission prompt, even though playback needs no media-library access.
+    On macOS all output is routed through ``afplay`` instead. This does NOT
+    affect audio *input* (recording), which legitimately needs microphone
+    permission. See PR #62601 / #13291.
+    """
+    return platform.system() != "Darwin"
+
+
+def _play_int16_via_tempfile(audio, sample_rate: int) -> None:
+    """Write int16 mono PCM to a temp WAV and play it via play_audio_file.
+
+    Used on macOS so tone/beep output goes through ``afplay`` instead of
+    sounddevice (avoids the TCC media-library prompt).
+    """
+    tmp_path = None
+    try:
+        tmp = tempfile.NamedTemporaryFile(suffix=".wav", delete=False)
+        tmp_path = tmp.name
+        with wave.open(tmp, "wb") as wf:
+            wf.setnchannels(1)
+            wf.setsampwidth(2)  # 16-bit
+            wf.setframerate(sample_rate)
+            wf.writeframes(audio.tobytes())
+        play_audio_file(tmp_path)
+    except Exception as e:
+        logger.debug("Tone tempfile playback failed: %s", e)
+    finally:
+        if tmp_path:
+            try:
+                os.unlink(tmp_path)
+            except OSError:
+                pass
+
+
 def _audio_available() -> bool:
     """Return True if audio libraries can be imported."""
     try:
@@ -419,9 +468,11 @@ def play_beep(frequency: int = 880, duration: float = 0.12, count: int = 1) -> N
         duration: Duration of each beep in seconds.
         count: Number of beeps to play (with short gap between).
     """
+    # Synthesize the tone with numpy only (no sounddevice import yet, so the
+    # macOS TCC prompt is not triggered on the synthesis step).
     try:
-        sd, np = _import_audio()
-    except (ImportError, OSError):
+        np = _import_numpy()
+    except ImportError:
         return
     try:
         gap = 0.06  # seconds between beeps
@@ -442,6 +493,16 @@ def play_beep(frequency: int = 880, duration: float = 0.12, count: int = 1) -> N
                 parts.append(np.zeros(samples_per_gap, dtype=np.int16))
 
         audio = np.concatenate(parts)
+
+        # On macOS, route the tone through afplay instead of sounddevice.
+        if not _sounddevice_output_allowed():
+            _play_int16_via_tempfile(audio, SAMPLE_RATE)
+            return
+
+        try:
+            sd, _ = _import_audio()
+        except (ImportError, OSError):
+            return
         sd.play(audio, samplerate=SAMPLE_RATE)
         # sd.wait() calls Event.wait() without timeout — hangs forever if the
         # audio device stalls.  Poll with a 2s ceiling and force-stop.
@@ -1306,10 +1367,11 @@ def play_audio_file(file_path: str) -> bool:
         logger.warning("Audio file not found: %s", file_path)
         return False
 
-    # On macOS, skip sounddevice entirely — PortAudio/CoreAudio init triggers
-    # a kTCCServiceMediaLibrary permission prompt even though we don't need it.
-    # afplay handles all formats natively without touching the media stack.
-    if file_path.endswith(".wav") and platform.system() != "Darwin":
+    # Skip sounddevice for output where it is not allowed (macOS): PortAudio/
+    # CoreAudio init triggers a kTCCServiceMediaLibrary permission prompt even
+    # though playback needs no media-library access. afplay (added to the
+    # system-player list below) handles all formats natively instead.
+    if file_path.endswith(".wav") and _sounddevice_output_allowed():
         try:
             sd, np = _import_audio()
             with wave.open(file_path, "rb") as wf: