Whats this even going into anyway? 200+ volts and 9Ah? Is it going into a drag bicycle? Even at 20C with those batteries, that's only 180A and it'l sag so bad you'd be lucky to get 150VDC out of them under that load.
That would be a problem only if the modules would be connected in series, but I'll connect them in parallel. When I'll connect a full module to an empty module in parallel, after a bit of time the charge will flow from the full battery to the full module to the empty module and both will become 50% full.
That would really complicate the design. You have to buss the first battery of the first module to the first battery of the second module. Then buss the second to the second, and so on. Just putting the "pack" in parallel with the other "pack" will not self balance. The packs will rest at the same voltage, but the cells will be all over the place.
I'd kinda tend to agree with RWAudio on this one.
Each module will be 64s3p, if I connect three modules together that'll make 64s9p. Batteries connected in parallel self-balance, yes?
so you want to connect 192 togther and have 3 modules? good luck. Its going to be a large task. I'm assuming you're using the 18650's. I've welded packs of 120 cells a piece, maybe 6 packs, and that was a REAL pain. Realize, you have 2 connections. that's 1280 welds, and you usually have to have 2 welding points, so 2560 welds. Forget about soldering.
Concerning Headways, did you read this:
http://www.zeva.com.au/tech/headway/
It suggests Headways don't perform too well.
You realize that test was done 3 years ago, right? Those cells have come a LONG way since then, and I've tested them. I mean, its ok for companies to continuously improve products isn't it? Well good news, they have.
Googling a bit I found many sources cite max charge of Headways at 2C, and some at 6C. I wonder why?
2C was 2 years ago. 6C is their current spec. Sometimes thats just how things are with China. The datasheets direct from headway state 6C max charge current on the newest cells. Some of the info is outdated because the "resellers" are lazy. I'll put that on my to do list of things to test.
At 6C they would be better then A123s! And if it would be so, then everyone would be excited about Headways on forums and not about A123 as it is now.
They're not BETTER for power, they're better for cost, ease of assembly, form factor, energy density and the ability to get legit cells with a WARRANTY.
As far as people on the forums being excited about A123, Maybe in RC and the bicycle forums, but from what I have witnessed in the last year or two around here are more interested in TS, CALB, GBS and Headway.
And what about cycle life? B-grade A123s can be bought at 2.05$ per Ah shipped, and what is the cheapest price you can get Headways (shipped) now? In quantities of up to 100Ah at a time?
As with all batteries, lifecycle depends on their use. If they're used no more than 20% DOD, you can get well over 2000 cycles.
As far as cost.... $2.05 an Ah shipped..... 100Ah is only 10 cells... so thats not really a very "large" quantity. Now, lets say you want the equivalent of 64S9p of the 1Ah cells, so about 64 cells of the 10Ah, thats something we stock, but its not a very large quantity of cells. Shipping wouldn't be that bad. I bet on 64 cells of 10Ah, they'd run about $18-19 + shipping, so lets say (worst case) $1216 + maybe $35 shipping + $25 hazmat = $1276. Now, compare that to buying the same thing 64s10p (equivalent pack), at 2.05. It works out to be just slightly more, $1312. Except you get no warranty, have to figure out how to weld 640 batteries, don't know if they're legit or not, and did I mention, its 640 frickin cells.
Headways are down below $1.80/Ah in quantity and TS and CALB are around $1.25/Ah in quantity. Shipping depends on how many you buy, cost goes down the more you order.