Body-Worn Camera

Application Overview

Body-worn cameras (BWCs) are widely used by law enforcement agencies to record video, audio, and images during patrols, traffic enforcement, and on-site operations. These devices must operate continuously throughout long duty shifts while maintaining stable performance during high-definition recording, infrared night vision, and wireless data transmission.

To meet these demands, PKCell provides a customized lithium battery solution designed specifically for body-worn camera applications, delivering long runtime, high reliability, and compact integration.

Customer Background

The customer is a law enforcement equipment provider serving police departments in Spain and other European regions. Their body-worn cameras are deployed for daily patrol operations, emergency response, and evidence collection.

Typical usage scenarios include:

• Continuous HD video recording throughout an entire shift

• Infrared night vision during low-light and nighttime operations

• High power demand during emergency events and data transmission

• Frequent charging cycles under intensive daily use

For these applications, battery failure or unexpected power loss is unacceptable, as it may compromise critical evidence recording.

Power Challenges in Body-Worn Camera Applications

Body-worn cameras present several unique power challenges compared with consumer electronics:

• Limited internal space requires a compact battery design

• High peak current demand during night vision and wireless transmission

• Long continuous runtime needed to cover full duty shifts

• Harsh operating conditions, including drops, vibration, and temperature variation

• Strict safety and compliance requirements for law enforcement equipment

Standard off-the-shelf batteries could not fully meet these requirements, prompting the need for a dedicated lithium battery pack solution.

PKCell Lithium Battery Solution Overview

PKCell developed an integrated lithium-ion battery pack tailored to the electrical, mechanical, and safety requirements of body-worn cameras.

The solution focuses on:

• High energy density within a limited volume

• Stable discharge performance for video and night-vision operation

• Enhanced safety through an integrated battery management system (BMS)

• Mechanical robustness suitable for law enforcement environments

This customized approach ensures reliable power delivery without increasing device size or weight.

Battery Configuration Design

Battery Chemistry & Structure

• Cell chemistry: Lithium-ion (NMC)

• Cell type: 18650, 3350mAh

• Pack configuration: 1S2P

• Nominal voltage: 3.6V

• Typical capacity: 6700mAh

• Rated energy: approximately 24Wh

This configuration balances compact size, lightweight design, and sufficient energy capacity to support extended recording time.

Electrical Performance

The battery pack is optimized to handle both continuous operation and short-term peak loads:

• Continuous discharge current: ≥ 3A

• Peak discharge current: ≥ 6A (infrared night vision and data transmission)

• Charging method: CC/CV

• Maximum charging rate: 1.5C

• Typical full charge time: approximately 2.5 hours

Stable voltage output ensures uninterrupted recording even during high-power events.

Battery Management System (BMS)

Integrated BMS Protection Functions

The battery pack integrates a low-power BMS designed for portable law enforcement devices, providing comprehensive protection:

• Overcharge protection

• Over-discharge protection

• Overcurrent protection

• Short-circuit protection

• Over-temperature protection

Smart Monitoring & Communication

• Accurate state-of-charge (SOC) estimation (≤ ±5% error)

• Optional I²C / SMBus communication interface

• Real-time reporting of voltage, current, and temperature

• Event logging for abnormal battery behavior

This intelligent management improves safety, reliability, and long-term battery health.

Mechanical & Thermal Design

To withstand demanding field conditions, the battery pack incorporates robust mechanical and thermal features:

• Flame-retardant enclosure materials compliant with UL94 V-0

• Internal shock-absorbing insulation for enhanced drop resistance

• Optimized cell layout for effective heat dissipation

• Temperature rise during continuous recording ≤ 10°C

The compact form factor is precisely matched to the camera housing for seamless integration.

Safety & Compliance

The battery solution is designed to meet international safety and regulatory requirements for law enforcement equipment:

• UN38.3 – Transportation safety

• IEC 62133 – Battery safety

• CE – Product conformity

• RoHS – Environmental compliance

These certifications ensure the solution is suitable for global deployment and international tenders.

Performance Results

Under real-world operating conditions, the battery solution delivers:

• Continuous recording time: 12–14 hours at 1080P

• Battery weight: approximately 90 g

• Cycle life: ≥ 600 cycles at 80% remaining capacity

• Operating temperature range: –10°C to +50°C

The battery maintains stable performance across long duty shifts and repeated charging cycles.

Customer Value

By adopting PKCell’s customized lithium battery solution, the customer achieved:

• Full-shift operation without battery replacement

• Reduced maintenance and battery replacement costs

• Consistent performance across large-scale deployments

• Improved device reliability and officer usability

Scalability & Future Expansion

The battery platform is scalable and can be extended to support future product development, including:

• Higher-capacity battery options for 4G/5G live streaming body-worn cameras

• Swappable battery designs

• Centralized multi-slot charging docks

• Battery solutions for related law enforcement devices such as PDAs, radios, and camera accessories

Looking for a Custom Lithium Battery Solution?

PKCell provides tailored lithium battery solutions for body-worn cameras and other professional law enforcement equipment.