We installed the Multi-Sensor Fusion Controller on our secondary smelting furnace about five weeks ago. The previous setup used separate thermocouple readers with manual logging, which meant someone had to walk the floor every hour to check temperatures. That was fine for batch work, but we are running continuous shifts now, and the old method could not keep up.
The controller itself was straightforward to wire into our existing Modbus network. The team from Multiconvergent spent two days on site, mostly on configuration and testing the failover logic. I was skeptical about the 50-millisecond switchover claim, but we tested it by pulling the primary PLC power during a stable melt, and the secondary took over without any visible temperature spike on the dashboard. That alone saved us from what would have been a scrapped batch if it had happened during a critical phase.
What I appreciate most is the centralized view. Instead of flipping between four separate displays, I now see all 32 thermocouple readings on one screen. The gradient map is useful for spotting cold zones near the tap hole, which we had not noticed before because the individual readings looked normal. We have already adjusted the burner angle on that side, and the temperature distribution is more even now.
There is one thing I would mention: the initial calibration took longer than expected because the thermocouple types were mixed (type K and type R on the same loop). The controller handled it after a firmware update, but it would have been smoother if we had standardized the sensors beforehand. That is on us, not on the hardware.
Overall, the system has been stable. No unexpected reboots, no data gaps, and the alarm thresholds we set have triggered correctly every time. I plan to order a second unit for the larger furnace next quarter.