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  • A manageable assembly size. A single module with 200 or 300 cells is pretty heavy and would need 2 hands to hold it, harder to move around and keep extra modules. At ~50g/cell, 200 cells weigh 10kg and 200 cells weigh 15kg. Smaller modules are easier to handle.

  • If a module fails, we need to replace the module. If we had only 4 modules in the pack, then we may only have the budget for a single spare module. Also, since there are more cells in a larger module, there is a greater chance that a cell within that module fails. Smaller modules means we can have more spare modules, and will statistically fail less often.

    • It is beneficial to make all modules exactly the same. Then we only have to keep 1 type of spare module, and any spare module can be swapped in for another. MSXII had 2 types of modules (and end module and a middle module) and we ended up running out of spare end modules, while still having a few spare middle modules unused.

  • More modules mean that we have more inter-module connections. This increases the number of failure point. Each inter-module connection also has a small resistance associated with it, so more connections means higher resistance in the pack’s current path, and more power loss (P = I^2 * / R).

  • If you compare the weight of the cells in a module to the weight of the rest of the items (cell holders, support brackets, cables, bolts, etc.) then the weight of the extra stuff in a larger module will be smaller per cell (LM = Large Module, SM = Small Module):

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