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Maybe you could have a file for each component you have in your robot and include them together in one single file for a robot, like I for example did here:
https://github.com/Hacks4ROS/h4r_rapid_robot_xacros/blob/develop/defs/test_robots/diff_drive_bot.xacro
There you probably could also set parameters changing for each robot. So every robot version would have it's own "tiny" file including all components it has and the changed parameters for the components.