Body-Cam battery: Why quality assurance is crucial for safety Swollen batteries, recalls, fire hazards: Body cameras are currently making headlines due to battery problems. Police forces in North Rhine-Westphalia, Baden-Württemberg and Saxony-Anhalt have already had to take devices out of service. But what is behind these problems – and how can similar problems be avoided?

When emergency services personnel put on their body cameras in the morning, they probably don’t think about battery technology. They rely on the device to work – for hours on end, in all weather conditions, in stressful situations. The small camera is designed to document operations and serve as evidence. But this very matter-of-factness is the result of complex technical processes that begin long before the first deployment.

In this article, we explain why a rechargeable battery can become problematic, what warning signs indicate wear and tear, and how consistent quality assurance can help avoid risks. * * * ## Body cameras out of service due to battery problems Recent incidents have brought the issue into focus: in several federal states, devices have been confiscated due to battery problems. The police forces in North Rhine-Westphalia and Baden-Württemberg were particularly affected. Body cameras also had to be taken out of service in Saxony-Anhalt recently – similar problems to those in other regions. A visible warning sign: in several cases, the cells in the affected batteries swell up. This creates a gap between the camera and the carrier plate. This small gap indicates that the battery is impaired or defective and needs to be replaced. Problems with body cameras are not an isolated case. The same technology is also repeatedly making headlines in smartphones, e-bikes and laptops. The causes are often identical: production errors, material fatigue or thermal wear.

- - How does the battery in a body camera work? Most body cameras use lithium polymer or lithium-ion batteries. These types offer high energy density: they store a lot of energy while being lightweight – ideal for a device that is worn on the body all day long.

How it works: during discharge, lithium ions migrate from the negative electrode (anode) through an electrolyte to the positive electrode (cathode). During charging, the process is reversed. Between the electrodes is a wafer-thin separating layer, known as the separator. This prevents the electrodes from touching, which would cause a short circuit.

This is precisely where the risk lies: the high energy density that makes the accumulator so powerful becomes a hazard if the separator is damaged by wear or defects. * * * ## Why do accumulators swell up? A defective or conspicuous accumulator typically goes through several phases:

Phase 1: Internal damage due to wear and tear Production errors, mechanical damage or natural wear and tear of the batteries can cause damage to the separator. Dendrites (metallic deposits) can also grow. These defects are usually not visible from the outside – the cell does not yet appear to be abnormal.

Phase 2: Affected batteries swell up Chemical reactions inside the battery cause gases to form. The affected batteries often swell up – a clear warning sign. In body cameras, this manifests itself in a small gap between the camera and the mounting plate. The device no longer fits properly into the holder.

Phase 3: Thermal runaway If an internal short circuit occurs in such cases, the cell heats up quickly. Once a critical temperature is reached, a chain reaction begins. The battery can melt, catch fire or, in extreme cases, explode. Damage patterns show how dangerous this process can be.

- - Similar problems: Not just with body cameras The incidents are part of a long list: * ✓ Samsung Galaxy Note 7 (2016): Samsung had to recall millions of devices due to battery problems. The damage: several billion euros and a massive loss of reputation.
✓ E-bike batteries: Defective pedelec batteries repeatedly cause garage fires. Fire brigades warn against charging e-bikes unattended. * ✓ Laptops and tablets: HP, Dell, Apple – virtually every major manufacturer has already had recalls due to faulty batteries.
✓ Body cameras in Germany: Police forces in North Rhine-Westphalia, Baden-Württemberg and Saxony-Anhalt have reported similar problems with swollen cells. * * * ## What should procurers look out for when purchasing body cameras? Authorities and companies that procure devices would do well to take a closer look. The following questions will help to avoid problems:

1. What testing processes does the battery undergo? A simple visual inspection is not enough to detect internal defects or incipient wear. Reputable manufacturers rely on multi-stage quality controls: at the supplier, on receipt of goods and before installation. The more testing stations, the lower the risk.

2. Is there active battery management? Modern body cameras should have integrated electronics that continuously monitor charging current, voltage and temperature. A good battery management system (BMS) detects abnormal values at an early stage and can interrupt the charging process.

3. How is wear and tear detected and documented? ### 4. Is the body camera suitable for continuous use? Not every small camera is suitable for professional use. Make sure that the device is designed for continuous operation and that the recordings can be used as evidence in court.

- - Detecting wear: from X-rays to computer tomography The most reliable method for detecting internal defects and wear is non-destructive testing. This involves examining the battery without opening or damaging it. It provides two-dimensional images of the interior. Major defects such as foreign particles or severely deformed electrodes become visible. However, this method is often not sufficient for a detailed analysis. The gold standard method. Combining multiple X-ray images creates a three-dimensional image. Even the finest cracks, dendrite growth or irregularities become visible – before the cell is impaired or defective. The damage images from the CT analysis show precisely where problems arise.

Industrial CT systems are ideal for quality assurance. In Germany, Microvista GmbH – a sister company of NetCo Professional Services – offers such tests as a service. * * * ## Practical example: How NetCo avoids problems As one of the few German manufacturers in the professional segment, NetCo has developed a multi-stage safety concept:

✓ Before installation: Each battery undergoes three test stations – at the cell manufacturer, upon receipt of goods in Blankenburg and again before assembly. If necessary, random samples can be examined using CT to detect damage at an early stage.
✓ During operation: An integrated battery management system continuously monitors the cell. Charging current and temperature are documented, and abnormal values are detected before problems arise. * ✓ After delivery: Devices are regularly serviced as part of refurbishing agreements. Accumulators showing signs of wear are gradually replaced. This ensures that the body camera continues to function reliably even after years of continuous use and remains suitable as evidence. The result: no safety-related incidents have occurred among long-standing customers, including police authorities and transport companies throughout Germany. * * *

Conclusion: Similar problems can be avoided The incidents involving the police in North Rhine-Westphalia, Baden-Württemberg and Saxony-Anhalt show that this issue deserves more attention. Devices had to be withdrawn due to battery problems – in several cases due to conspicuous or bloated batteries, among other things – but similar problems can be avoided through consistent quality assurance.

For purchasers, this means not only paying attention to features and price, but also asking how the manufacturer deals with wear and tear and quality control. Check whether the body camera is suitable for continuous use and whether recordings can be used as evidence. Ultimately, it is about the confidence of the emergency services in their equipment – and their safety.

- - Would you like to learn more about the safety of the NetCo Body-Cam Pro? * ✓ View technical data * ✓ Request a consultation * ✓ CT testing by Microvista

Body-Cam battery: Why quality assurance is crucial for safety

Table of contents * Body-Cam battery: Why quality assurance is crucial for safety * Body cameras out of service due to battery problems * How does the battery in a body camera work?

How does the battery in a body camera work? Most body cameras use lithium polymer or lithium-ion batteries. These types offer high energy density: they store a lot of energy while being lightweight – ideal for a device that is worn on the body all day long.

Phase 3: Thermal runaway If an internal short circuit occurs in such cases, the cell heats up quickly. Once a critical temperature is reached, a chain reaction begins. The battery can melt, catch fire or, in extreme cases, explode. Damage patterns show how dangerous this process can be.

Similar problems: Not just with body cameras The incidents are part of a long list: * ✓ Samsung Galaxy Note 7 (2016): Samsung had to recall millions of devices due to battery problems. The damage: several billion euros and a massive loss of reputation.

2. Is there active battery management? Modern body cameras should have integrated electronics that continuously monitor charging current, voltage and temperature. A good battery management system (BMS) detects abnormal values at an early stage and can interrupt the charging process.

3. How is wear and tear detected and documented? ### 4. Is the body camera suitable for continuous use? Not every small camera is suitable for professional use. Make sure that the device is designed for continuous operation and that the recordings can be used as evidence in court.