Open source IoT-based SCADA system for remote cutting temperature monitoring using Node-RED and NodeMCU

The significant heat generated by plastic deformation and friction during machining affects chip formation, tool wear, workpiece surface integrity, and quality, making it crucial to measure the temperature in real time to optimize cutting parameters, enhance machinability, reduce costs, and improve tool life and productivity. This paper presents an open-source and low-cost Supervisory Control and Data Acquisition System based on Node-RED and Node MCU microcontrollers. The system is designed for wireless remote monitoring and supervision of in-situ 8-channel thermocouple measurements deployed in machining bone substitute material using innovative ceramic cutting inserts. The Node-Red is a programming tool is used to deploy a server on a host computer, and two NodeMCU ESP32 terminal devices are linked to it to form the internet of things (IOT) based SCADA System. The primary function of these units is to gather real-time temperature data obtained from eight k-type thermocouples positioned at distinct locations beneath the cutting paths. Communication between the NodeMCU units and the Node-RED server on the computer occurs over a virtual machine. Furthermore, a graphical user interface (GUI) is developed using Node-RED and is hosted on the local server to facilitate the parsing of the gathered data. Finally, to enhance the dependability and the security of the local server, authentication through HTTP is implemented in the webserver, thereby regulating clients’ access from the Internet.