Digital control valve system with auto tune valve and piston

Abstract

The present disclosure relates to an improved digital control valve (DCV) system (100), featuring a piston-type design with a stepped piston and dual piston seals for precise flow rate control and enhanced batch accuracy under fluctuating upstream pressure (P1) conditions The piston (302) is hydraulically balanced to ensure smooth operation and reliable batch filling. The disclosure provides an Auto Tune Valve (ATV) (200) in place of conventional manually operated needle valves, offering tamper-proof, automated tuning based on line pressure by dynamically varying internal orifice size, thereby eliminating manual adjustment efforts. The improved DCV system is designed to addresses the challenge of closing the valve during electrical or mechanical failures, ensuring safety and environmental protection during batch filling operations. Two distinct dampening mechanisms are employed to mitigate sudden ramping up or down during pressure fluctuations, reducing vibration, noise, and stress on components, thereby enhancing reliability and service life. The improved DCV system ensures efficient, automated operation under varying conditions, delivering consistent safety and performance.

Description

DIGITAL CONTROL VALVE SYSTEM WITH AUTO TUNE VALVE AND PISTONFIELD OF INVENTION

[0001] The present disclosure relates to fluid flow controlling device and, more particularly, to a digital control valve system having an improved piston for fluid flow control.BACKGROUND OF THE INVENTION

[0002] The subject matter discussed in the background section should not be assumed to be prior art merely because of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may correspond to implementations of the claimed technology.

[0003] Digital control valve is similar to conventional piston but as an opening area in valve is digitally controlled by solenoid valve therefore it is called Digital control valve. These valve (DCV) are critical in application / industries where the fluid is expensive (like Oil, Gas, Petroleum products etc.) and precise control in fluid flow and batch filling is essential. These valves regulate flow, pressure, and liquid levels by fully or partially opening or closing. Also ensure the accuracy for the amount of liquid filled in a tank.

[0004] Conventional DCV valve uses manual operated needle valve. This needle valve is used to control the rate of opening and closure of piston and facilitate complete DCV to operate precisely at set line pressure. This manual tuning is person specific (skilled person is required), time consuming, imprecise and does not work accurately with fluctuating line pressure. These manual needle valve can be easily tampered by anyone and will lead to in-accurate flow control during operation. Some people use locks on the needle valve to eliminate the tampering of the DCV valve, however additional locking arrangement will lead to additional cost to users. Even inline maintenance of these valves is also a difficulty, as during maintenance, along with needle valve, adjacent tube and fitting also need to be removed. This leads to higher maintenance time. Automated mechanisms, using electric, hydraulic, or pneumatic actuators controlled by positioners, provide some level of precision but remain limited in response time and ease ofcontrol. Existing DCV valves tend to perform poorly under high upstream and downstream pressures, leading to inefficiencies in the accuracy of a liquid batch filling.

[0005] In existing DCV systems, manual operated needle valves are used to regulate the rate of opening and closing of a piston in order to achieving the target flowrates in a control manner at set pressure. These devices are designed to dynamically adjust flow conditions but suffer from several technical limitations. For example, conventional manual operated needle valve in the system have a fixed set orifice area for flow even during varying or fluctuating pressure. The manual needle valve may not fully adapt to varying upstream and downstream pressure conditions or may introduce delays in regulating fluid flow. Such limitations increase an error and impact on providing accuracy in batch filling of liquids resulting in monetary loss to the user which would be notable fraction if the limitations persist for several batch filling, increase the risk of inconsistent flow control, and heighten the likelihood of operational inefficiencies under changing conditions. Additionally, reliance on manually operated needle valves introduces further challenges. Manual operation increases the risk of human error, resulting in inaccurate flow adjustments and delayed closure of the piston. In emergencies or during mechanical or electrical failures, such delays can lead to uncontrolled fluid flow, posing significant safety and environmental risks.

[0006] The two types of technology that exist in DCV - Diaphragm DCV and Piston. These two types of DCV uses needle valve and limitations related to manual operated needle valve which exist with both types of DCV. In addition, the diaphragm DCV technology has the limitation due to failure of flexible diaphragm after limited usage, fatigue failure, wear failure etc. The limitations lead to higher maintenance time, lower MTBF (mean time between failure) higher spare cost which lead to higher operating cost. With diaphragm failure, DCV become in-consistent in fluid flow control and valve does not adjust with fluctuating line pressure and flow. This led to over filling and under filling of fluid. Over filling leads to notable monetary loss to a seller. Over filling / Underfilling at a point of sale application will result in monetary loss to the buyer or seller of expensive fluid.

[0007] The existing conventional Piston type DCV has additional limitation along with manual operated needle valve. The piston design is such that the closing force on piston is entirely dependent on a spring above the piston. This dependency limits the valve repeatability. Thesevalve work does not tune itself to fluctuating pressure conditions therefore limit its performance and lead to in-accurate filling (under or over filling). Such limitations reduce overall system efficiency, increase the risk of inconsistent flow control, and heighten the likelihood of operational inefficiencies under changing conditions.

[0008] In addition to above limitation, there is a safety and environmental risk during spring failure. The valve will not close during spring failure and may lead to over filling and over filling may lead to overflowing of fluid from the tank and poses environmental risk, if fluid is flammable, eventually it may poses to big environmental and safety risk to the complete site and area along with which operates working nearby. Further, in conventional piston if piston O-ring fails or does not functions then the fluid will leak or exfiltrate to downstream side of DCV and will lead to over filling or leakage to the Atmosphere that also poses environmental and safety risk.

[0009] In existing conventional DCV due to incapability to regulate the flow with fluctuating pressure due to use of manual needle valve, these valve does not present from sudden ramp up and ramp down. This sudden ramp up and ramp down creates impact load on valve internal parts and further lead to reduced service life of the internal parts. These impact load further generate noise and vibration in the line that impact the adjacent equipment and integrity of the complete system. Also, these create environment and safety risk for the complete system and users.

[0010] To address these challenges, it is necessary to develop advanced DCV valve that integrate improved piston designs and enhanced assemblies such as Auto tuned valve instead of manual needle valve. A key limitation of conventional systems is the inability to prevent sudden ramping down of pistons, which can damage the valve assembly and compromise operational accuracy, flow stability and also an inability of the conventional system to more effectively control valve at varying upstream pressure. Improvements in valve design, such as incorporating structural enhancements like calibrated gaps, slots, or cushioning mechanisms, allow for smoother ramp-down, protecting the assembly without compromising performance. Such designs must ensure controlled fluid flow and pressure stabilization to enhance operational safety and precision.

[0011] Thus, there exists a need for an improved DCV system with an advanced piston design and an integrated, enhanced ATV assembly to overcome the limitations of conventional technologies. Such a system should enhance safety, precision, and efficiency while extending the service life of the valve in high-pressure fluctuating application.OBJECT OF THE INVENTION

[0012] The object of the present disclosure is to provide an improved digital control valve with no manual intervention and tamper free valve.

[0013] The object of the present disclosure is to provide an improved digital control valve by replacing the manual needle valve with an auto-tune valve (ATV).

[0014] The object of the present disclosure is to provide an improved digital control valve with high repeatability in fluid flow rate control and precision filling under fluctuating line pressure.

[0015] The object of the present disclosure is to provide a digital control valve with improved trim design so as to quickly respond to electrical or mechanical failures and facilitate the closing of the piston to eliminate the environmental and safety risk.

[0016] Another object of the present disclosure is to provide a digital control valve having a piston capable to self-adjust to fluctuating fluid pressure and maintain flow controllability and batch accuracy.

[0017] Still another object of the present disclosure is to provide improved digital control valve with smooth ramp up and ramp down under fluctuating fluid pressure.

[0018] A further object of the present disclosure is to provide a dampening assembly for preventing sudden ramp-down of the piston and ensuring smooth operation of the main valve.

[0019] The object of the present disclosure is to provide an improved digital control valve with low noise and pipeline vibration created due to pressure oscillations caused by rapid opening and closing of the DCV which facilitate improved service life of components.

[0020] The object of the present disclosure is to provide a digital control valve system capable of responding to mechanical or electrical failures by ensuring automatic closure of the main valve to prevent overfilling or flooding.

[0021] The object of the present disclosure is to provide an improved digital control valve with lower pressure drop and high valve coefficient (Cv).

[0022] The object of the present disclosure is to provide an improved digital control valve that facilitates the inline maintenance.

[0023] Another object of the present disclosure is to provide a stepped piston design which allows for higher operational safety by having lower risk of O-ring failure as well as under nonoperating condition a positive valve closure is achieved by the higher piston force.SUMMARY OF THE INVENTION

[0024] The summary is provided to introduce aspects related to a digital control valve for managing fluid flow pressure, and the aspects are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining or limiting the scope of the claimed subject matter.

[0025] In one embodiment, the present disclosure provides a digital control valve system for controlling fluid flow, comprising: a cylindrical valve chamber, a piston housed within the cylindrical valve chamber, the piston having: a body section, and an annular sealing ring protruded to direct pressure at an annular area towards the body section, a plurality of solenoid valves, including: a normally open (NO) solenoid valve connecting the valve chamber to an upstream pressure (Pl), a normally closed (NC) solenoid valve connecting the valve chamber to a downstream pressure (P2), an electrical controller configured to selectively energize and de-energize the solenoid valves to create differential pressure in the valve chamber for actuating the opening and closing of the piston, and at least one dampening mechanism within the cylindrical valve chamber for regulating the movement of the piston, wherein during the upstream pressure (Pl), the piston is configured to direct fluid flow pressure onto the annular area of the protruded annular ring to distribute pressure to a larger surface area of the piston.

[0026] In an embodiment, in the digital control valve system, the piston, seated with an O-ring, positioned above the annular area, wherein the assembly of the piston with the O-ring creates sealing pressure during closing of the DCV at higher differential pressure across the piston. Even if the O-ring fails to create sealing pressure the fluid exfiltrate to the upstream side facilitating to the closing of the piston of the DCV.

[0027] In an embodiment, a manifold assembly housing a plurality of auto-tune valves (ATV), wherein the manifold assembly is positioned at periphery of the digital control valve system, and each auto-tune valve (ATV) comprises a tapered valve stem with a slender, tapered point incorporated in holes at an end of a valve stem, serving as a throttle valve. Further, each autotune valve (ATV) comprises a plurality of springs housed in a C-ring structure for controlling needle-like structures, poppets, and the fluid flow, and a poppet integrated with strategically positioned apertures for enabling self-adjustment of the valve stem position in response to varying upstream (Pl) and downstream pressure (P2) conditions, wherein the poppet dynamically adjusts the size of an orifice to provide automated tuning of fluid flow.

[0028] In an embodiment, the manifold assembly houses at least two auto-tune valves positioned symmetrically for balanced fluid flow. Furthermore, the manifold assembly has a screw-in cartridge valve construction for facilitating maintenance and inspection of the autotune valve without disassembling an entire digital control valve.

[0029] In an embodiment, the poppets are configured to self-determine in response to varying upstream or downstream pressure (Pl, P2) fluctuations and move laterally within the ATV to adjust the size of the orifice.

[0030] In an embodiment, in the digital control valve (DCV) system (100) comprises at least one dampening mechanism. The dampening mechanism ensures opening or closing of valve by regulating the movement of the valve at a controller flow rate compensating for varying pressure condition. In the digital control valve system, at least one dampening mechanism may be a hydraulic dampening assembly. The hydraulic dampening assembly is integrated within the piston chamber and comprises a cavity formed within the piston, the cavity including a middle cavity positioned between an upper cavity and a lower cavity, a side wall surrounding the middle cavity, the side wall comprising one or more orifices to control fluid flow betweenthe middle cavity and adjacent cavities, wherein the cavities are configured to enable controlled fluid transfer during movement of the piston.

[0031] In an embodiment, the hydraulic dampening assembly comprises: a plurality of hydraulic passages between the upper cavity, middle cavity and lower cavity, the hydraulic passages comprises: (a) smaller orifices in the upper cavity for restricting the fluid flow during upward movement of the piston to reduce sudden pressure fluctuations, (b) larger orifices in the middle cavity to accelerate fluid evacuation from middle cavity with large orifices to upper cavity with small orifices during downward movement of the piston, wherein the hydraulic passages are configured to direct fluid between the cavities to stabilize the piston during ramp- up and ramp-down operations.

[0032] In an embodiment, the fluid flows from the middle cavity with larger orifices to the upper cavity with smaller orifices during ramping down of the piston. Further, the hydraulic dampening assembly comprises the middle cavity with a larger area connected to the upper cavity through hydraulic pipes, the hydraulic pipes incorporating a plurality of bigger holes configured to increase the speed of fluid flow from the middle cavity to the upper cavity, wherein an increased fluid flow through each of the holes in the hydraulic pipes accelerates the fluid evacuation of fluid from the middle cavity and reduces the pressure in the middle cavity, and the reduced ramp-down speed of the piston to prevent sudden closure of the piston, ensuring smoother operation of the digital control valve.

[0033] In an embodiment, the hydraulic dampening assembly includes a check valve with an orifice in the middle cavity to facilitate controlled fluid transfer between the middle cavity and adjacent cavities during operation.

[0034] In yet another embodiment, at least one dampening mechanism comprises a trim design of the piston, the trim design including a slot at an outer surface of the piston, wherein the slot is seated with an O-ring positioned at an operational distance from an edge of the slot and the O-ring being configured to cushion the piston during ramp-down.

[0035] In an embodiment, a gap provided between the piston and a cylindrical cover surrounding the piston has a calibrated width at the edge of the slot tailored to allow intentional minimal fluid flow for reducing ramping down speed of the piston.

[0036] In yet another embodiment, the controller detects reduced flow rates through the gap before the piston contacts the O-ring and sends a signal to the solenoid valves to increase upstream pressure (Pl) and lift the piston to prevent sudden ramping down of the piston.

[0037] In a further embodiment, the present disclosure provides an auto-tune valve (ATV) for a digital control valve system, comprising: a manifold assembly housing a plurality of autotune valves (ATV), the manifold assembly being linearly constructed and positioned at the periphery of the digital control valve system, enabling independent access and maintenance of each of the plurality of auto-tune valves (ATV) without disassembling the entire digital control valve system, each of the plurality of auto-tune valve (ATV) comprises: a tapered valve stem with a slender, tapered point incorporated in holes configured to adjust an orifice, a poppet integrated with strategically positioned apertures for enabling self-adjustment of the valve stem position in response to varying upstream pressure (Pl) and downstream pressure (P2) conditions, a spring mechanism housed in a C-ring structure configured to exert controlled force on the poppets for precise regulation of fluid flow, a conduit interface between the manifold assembly and the digital control valve system for fluid communication, wherein the plurality of auto-tune valve (ATV) dynamically modulates the fluid flow by adjusting the orifice size in response to differential pressure conditions and provides automated tuning of the fluid flow without manual intervention.

[0038] In an embodiment, the manifold assembly is secured by screws and is configured for independent attachment to the digital control valve system. Further, the manifold assembly includes a screw-in cartridge valve construction to facilitate maintenance and inspection of the plurality of auto-tune valves without disassembling the entire digital control valve system.

[0039] In an embodiment, each of the auto-tune valve (ATV) is configured to dynamically adjust the orifice size by lateral movement of the poppets in the response to differential pressure conditions between the upstream pressure (Pl) and the downstream pressure (P2).

[0040] In yet another embodiment, the present disclosure provides a piston assembly for a digital control valve, comprising: a cylindrical valve chamber housing a piston, wherein the piston comprises: a body section, and annular sealing rings protruded to direct pressure at an annular area towards the body section, a trim design incorporating: a slot seated with an O-ring, the slot having a base ring configured to protect the piston during ramp-down operations, a gap provided between the piston and the cylindrical cover surrounding the piston, the gap configured to allow controlled fluid flow through the slot for reducing a ramping speed of the piston, wherein the piston operates to open or close based on upstream pressure (Pl) and downstream pressure (P2) differentials within the cylindrical valve chamber, and wherein during upstream pressure, the piston is configured to direct fluid flow onto the annular area to distribute pressure to a larger surface area of the piston.

[0041] In an embodiment, the protrusions at a head section of the piston are configured to direct fluid flow into the annular area for controlled pressure distribution. Further, a pressurebalancing space is dimensioned to delay sudden valve closure during high upstream pressure (Pl) conditions.

[0042] In an embodiment, a fluid pressure in the piston is redirected to the annular area in the body section of the piston, reducing the pressure on the piston by 30%, significantly decreasing a time required for the main valve to close. Further, the piston closes against differential pressure conditions with a force reduced by 60%.

[0043] In another embodiment, the digital control valve system is configured to automatically close a main valve in an event of a mechanical failure, including spring or Piston O-ring failure; or in an event of an electrical failure, including complete terminal power outage or cessation of pump operation.BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

[0044] The accompanying drawings constitute a part of the description and are used to provide a further understanding of the present disclosure. Such accompanying drawings illustrate the embodiments of the present disclosure used to describe the principles of the present disclosure. The embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and they mean at least one. In the drawings:

[0045] Fig. 1 illustrates a schematic representation of the working principle of an existing conventional digital control valve system.

[0046] Fig. 2a illustrates a schematic representation of a manifold assembly housing a plurality of Auto Tune Valves (ATVs) of the digital control valve, in accordance with an embodiment of the present disclosure. Fig. 2b illustrates a sectional view of each of the plurality of Auto Tune Valves (ATV), in accordance with an embodiment of the present disclosure.

[0047] Fig. 3a illustrates a schematic representation of a conventional piston and its limitations, in accordance with prior art.

[0048] Fig. 3b illustrates a schematic representation of an improved piston with trim design and fluid flow for pressure distribution, in accordance with an embodiment of the present disclosure.

[0049] Fig. 4a illustrates the digital control valve assembly, in accordance with an embodiment of the present disclosure.

[0050] Fig. 4b illustrates the piston assembly with a dampening mechanism, showing slots and gaps designed for controlled ramp-down, in accordance with an embodiment of the present disclosure.

[0051] Fig. 5 illustrates the hydraulic dampening mechanism integrated within the digital control valve system, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION OF THE INVENTION

[0052] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present disclosure and is not intended to represent the only embodiments in which the present disclosure may be practiced. Each embodiment described in this disclosure is provided merely as an example or illustration of the present disclosure and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the present disclosure. However, it will be apparent to those skilled in the art that the present disclosure may be practiced without these specific details.

[0053] As used herein, the term “comprising” means including but not limited to and should be interpreted in the manner it is typically used in the patent context. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of.

[0054] The phrases “in one embodiment,” “according to one embodiment,” “in some embodiments,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0055] The present disclosure provides a digital control valve for managing and controlling fluid flow pressure. The digital control valve of the present disclosure is capable of providing enhanced system reliability, reducing maintenance requirements and downtime to improve the piston service life. The improved DCV system that leverages the precise control capabilities of an auto-tune valve. Through this integration, the present disclosure aims to enhance the accuracy, responsiveness, and versatility of fluid flow regulation in industrial settings. The subsequent sections of this patent specification will delve into the detailed description, features, and operational aspects of the inventive DCV system, emphasizing its unique contributions to the field of fluid flow control technology.

[0056] Fig. 1 illustrates the working principle of conventional digital control valve having a main valve (118) connected with a top cover, plurality of solenoid valves, for example at least two solenoid valves (110, 112) and a manual needle valve (108). The plurality of solenoid valves including a normally open (NO) solenoid valve (110) along with the manual needle valve (108) that connects an upstream line with pressure (Pi) and top cavity (116) of a “piston or plunger” (104). The plurality of solenoid valves includes a normally close (NC) solenoid valve (112) with manual needle valve (108) that connects top cavity (116) of the piston (104) to a downstream line with pressure (P2). The digital control valve uses an electrical controller (122) for operating the solenoid valves (110, 112) to energize and de-energize the solenoid valves (110, 112). The digital control valve houses the “piston or plunger” (104) for actuating the opening and closing of the main valve (118). The digital control valve comprises a spring located in between top cavity (116) and the piston (104) to create positive load to the piston (104) under non-operating condition. The top cavity (116) in the digital control valve alsoprovide a relative force against the exerted pressure and exhibits smooth to-and-fro movement of the piston. The condition when NO solenoid valve (110) and NC solenoid valve (112) are energized, the valves open; when NC solenoid (112) is de-energized (keeping NO solenoid (112) energized), the piston (104) locks at its current position; when NO solenoid (110) and NC solenoid (112) are de-energized, the main valve (118) closes gradually.

[0057] The NO solenoids (HO) and NC solenoids (112) initially are in a de-energized condition. The NO valve (110) applies high upstream pressure (Pi) on the main valve (118), whereas the NC valve (112) prevents this pressure from getting drained to the downstream side. The main valve (118) remains closed. The electrical controller (122) operated the solenoid valves (110, 112) to get energized. NO valve (110) now restricts the high upstream pressure (Pi) from entering into the top cavity (116) of the piston (104). NC valve (112) permits the pressure above the main valve (118) to vent to the low downstream pressure (P2). The differential pressure across the piston is created. The high upstream pressure (Pi) opens the main valve (118) and allows the flow to start. The NC solenoid valve (112) is de-energized as the flow rate reaches a predefined value and locks the valve (112). The opening and closing of the solenoid valve determine a differential pressure of the fluid flowing through a pipe (102) in a cylindrical valve chamber (120) of the digital control valve.

[0058] Fig. 2a illustrates a manifold assembly (214) housing a plurality of Auto Tune Valves (ATVs) of the digital control valve, in accordance with the present disclosure. As illustrated, in the manifold assembly (214) housing a plurality of Auto Tune Valves (ATV) (200), which are positioned strategically at the periphery of the digital control valve system. The manifold assembly (214) is designed to provide independent access to each ATV for simplified maintenance and repair without disassembling the entire digital control valve system. The linear construction of the manifold assembly (214) ensures a compact and modular design, enabling efficient space utilization and ease of integration into the larger digital control valve system.

[0059] Each ATV (200) is positioned within the manifold assembly (214) such that the valves are symmetrically aligned. This symmetry ensures balanced fluid flow during operation. The ATVs are connected to the manifold assembly (214) through threaded interfaces, which are secured using screws (212). These connections not only provide mechanical stability but alsoenable the independent detachment of individual ATVs for maintenance and replacement without disturbing the rest of the assembly.

[0060] The manifold assembly (214) incorporates internal fluid channels that are precisely aligned with the inlet and outlet ports of each ATV (200). These channels form a conduit interface that establishes seamless communication between the ATVs and the digital control cylindrical valve chamber (120). The conduit interface ensures that fluid can be directed to or from each ATV for modulation based on upstream (Pl) and downstream (P2) pressure conditions. The assembly (214) includes a screw-in cartridge valve construction that encloses and protects the internal components of the manifold assembly (214), such as the ATVs and their connecting channels. The cover is designed for easy removal, allowing for straightforward inspection, maintenance, and cleaning of the ATVs without requiring disassembly of the entire digital control valve system.

[0061] Each ATV (200) within the manifold assembly incorporates a tapered valve stem with a slender, tapered point. The tapered end of the valve stem is positioned within precisely machined holes at the end of the manifold channels. These holes act as throttle points, controlling the flow of fluid into or out of the ATVs. Additionally, each ATV is equipped with springs (204) housed within a C-ring (206) structure, which exerts controlled force on poppets (210). The poppets are integrated with strategically positioned apertures for fine adjustments to an orifice (202) size during operation. The manifold assembly (214) is further equipped with sealing rings around critical interfaces, ensuring high precision in fluid flow control and eliminating the risk of leaks. These sealing rings are positioned between the ATVs and the manifold body to maintain pressure integrity within the system.

[0062] Fig. 2b illustrates a sectional view of each of the plurality of Auto Tune Valves (ATV) (200). The ATV (200) is characterized by a tapered valve stem, which incorporates a slender, tapered point to serve as a throttle valve. This tapered point is integrated into holes (208) located at the end of the valve stem, providing precise control over fluid flow. The ATV is equipped with a plurality of springs (204) housed within a C-ring (206) structure. These springs exert controlled force on needle-like structures, poppets (210), which play a critical role in regulating the flow of fluids. The poppets (210) are strategically positioned within the valve system and are integrated with apertures to enable self-adjustment of their position in response to varying pressure conditions. The orifice (202) is a key component of the ATV, dynamicallyadjusting its size based on the lateral movement of the poppets (210). This dynamic adjustment allows the ATV to modulate fluid flow with exceptional precision.

[0063] During operation, the manifold assembly (214) dynamically manages fluid flow through the ATVs (200). As upstream pressure (Pl) enters the system, it is directed to the manifold assembly (214) via the internal channels. The fluid enters the tapered holes in the valve stems of the ATVs, where the slender, tapered point adjusts the size of the orifice (202). This adjustment is achieved through the movement of the poppets (210), which are actuated by the spring mechanism housed within the C-ring (206). The movement of the poppets (210) dynamically alters the effective orifice size, enabling precise regulation of fluid flow in response to changes in upstream (Pl) and downstream (P2) pressures. For instance, as Pl increases, the poppets (210) are pushed forward, reducing the size of the orifice and thereby controlling the flow rate. Conversely, when Pl decreases, the poppets retract, enlarging the orifice and allowing a higher flow rate to compensate for the reduced pressure. The symmetrical arrangement of the ATVs ensures balanced fluid flow within the manifold assembly (214). The interconnected channels within the manifold assembly (214) enable fluid distribution across all ATVs, providing uniform pressure modulation. This balance prevents flow imbalances and ensures that the digital control valve system operates efficiently under varying operational conditions.

[0064] The C-ring (206), featuring a spring mechanism, enhances the responsiveness of the valve, ensuring adaptability to both increases and decreases in upstream pressure (Pl). In an embodiment of the present disclosure, the poppets (210) exhibit a unique "Tea Pod" nature, featuring strategically designed holes (208) that optimize their positioning within the valve. As upstream pressure increases, the poppets (210) move toward the right side of the orifice (202), reducing the orifice diameter and effectively controlling fluid flow. Conversely, a decrease in upstream pressure causes the poppets (210) to shift toward the left, enlarging the orifice and allowing increased fluid flow to compensate for the reduced pressure.

[0065] The automated tuning capability of the ATV eliminates the need for manual adjustments, significantly reducing the risk of human error. The dynamic movement of the poppets (210) and the corresponding adjustment of the orifice size ensure responsive control over fluid flow rates. The ATVs design is optimized for adaptability to varying operational conditions, enhancing the reliability and efficiency of the digital control valve system.

[0066] The integration of the ATV within the manifold assembly (214), as shown in Figure 2a, provides a robust and scalable solution for fluid flow management. The strategic placement of the ATV within the system, combined with its dynamic tuning capabilities, ensures that the digital control valve system can operate with high precision and reliability under a wide range of pressure conditions.

[0067] Fig. 3a illustrates a schematic representation of the piston (302) in accordance with a general state of the art. In a design as depicted in fig. 3a, the upstream pressure (Pi) acts on a complete bottom portion (306) of the piston (302). At the top of the piston (302), the downstream pressure (P2) acts along with a spring pressure. In NC condition upstream pressure (Pi) is same as that of the piston (302) that helps to close the piston (302). In NO condition the forces, acting on bottom and top of the piston (302), are balanced and the piston (302) gets hydraulically lock at that position. As illustrated in this design, spring pressure is the only factor that generates a differential pressure that accesses the piston (302) closer and therefore the piston (302) closing rate remains constant in spite of upstream pressure (Pi) fluctuation. In accordance with an embodiment as illustrated in fig. 3a, there is high variation in batch filling, lower repeatability and accuracy. In an illustrated design, the condition in which the spring fails, the piston (302) will not get close and that will lead to overflooding of tank and eventually impact environment and also a safety risk is involved. The design of the general state of the art or conventional design comprising two O-ring (Piston O-ring & Seat O-ring) that resist the higher upstream pressure (Pi) to flow to downstream in close condition. In case, if either of the O-ring fails during operation or close condition, the fluid will start leaking to downstream and over flooding of the filling tank and eventually impact environment and also the safety risk is involved.

[0068] Fig. 3b illustrates a schematic representation of piston (302) in accordance with the present disclosure. The piston of the present disclosure introduces an enhanced trim design for digital control valves (DCVs), providing improved responsiveness and reliability compared to conventional designs. The innovative trim design results in a reverse flow of fluid and reduced pressure on the piston, thereby decreasing closing time and fluid flow rate and increasing overall efficiency. The trim design focuses on directing fluid pressure to the annular area surrounding the piston, rather than applying maximum pressure directly on the piston. In contrast to conventional digital control valves, where the fluid pressure acts directly on thepiston, the present disclosure incorporates a design that induces a reverse flow of fluid. This reverse flow redirects pressure to the annular area around the piston rather than applying it directly to the piston itself. The trim design ensures that the pressure acting on the piston is reduced by 30% compared to conventional digital control valves. This reduction in pressure on the piston is achieved by strategically directing the fluid pressure to the annular area, leading to more controlled and efficient valve operation. The reduced pressure on the piston significantly decreases the time required for the valve to close. In the event of mechanical or electrical failure, the reverse flow of fluid and the trim design contribute to a faster and more reliable closing of the piston compared to conventional designs. During mechanical or electrical failures, the present disclosure acts as a fail-safe closing mechanism. Since downstream pressure (P2) is designed to be more than upstream pressure (Pl) during the closing condition, the force acting on the piston ensures that the valve remains closed even in failure scenarios.

[0069] In accordance with an embodiment of the present disclosure, as illustrated in fig. 3b, the piston (302) includes a protrusion at the head section of the piston (302). The piston (302) includes a piston protected by a sealing area. The sealing area comprises a sealing ring (310) protruding at the head of the piston. The protrusion in the piston are directly exposed to the fluid at upstream pressure (Pi) and downstream pressure (P2). The digital control valve comprises the piston (302) with protruded sealing rings (310) in the piston positioned in the closed chamber (120) of the digital control valve. The protrusion in the piston direct the flow of the fluid into a body (308) of the piston. In an illustrated embodiment of the present disclosure, the pumping of the fluid in the digital control valve through a pipe (102) is directed in a direction opposite to the conventional pumping of the fluid in the conventional control valve as depicted in Fig. 1. The fluid is pumped, and the pressure exerted on the body (308) of the piston is upstream pressure (Pl), and at the head of the piston, it exerts downstream pressure (P2). The digital control valve comprises the piston (302) integrated into a valve chamber (120) wherein the protruded piston (302) is for modulating fluid flow.

[0070] In an exemplary embodiment as illustrated in Fig 3b, at the state when the upstream pressure (Pi) is greater than the downstream pressure (P2), the piston (302) opens and the fluid flows, and when the downstream pressure (P2) starts increasing due to the closing of the NC solenoid valve (112) located at the valve chamber (120) of the digital control valve, the differential pressure (P1-P2) decreases, thereby closing the piston (302). The piston (302),having protrusion in the piston, is adjusted in chamber (120) of the digital control valve such that the pumping of the fluid is directed towards the bottom portion (306) of the piston at any pressure.

[0071] In an illustrated embodiment, the differential pressure of the piston (302) at close direction is directed towards the body (308) of the piston. The protruded area of the piston exerts the force generated by the upstream pressure (Pi) and directs the force at a decreased fluid flow rate. The protrusion in the piston covers 40% of the area and thereby decreases the pressure to be directly exerted on the bottom portion (306) of the piston. Thus, the present disclosure relates to an improved digital control valve providing precise and efficient control of the fluid flow, in which components, for instance, the protruded piston (302) installed in the chamber (120) of the digital control valve thereof closes against 60% less force. The pumping of the fluid in accordance with the digital control valve system of the present disclosure provides the increased service life of the components, particularly the increased service life of the piston. The digital control valve system of the present disclosure is capable of providing enhanced system reliability, reducing maintenance requirements, and reducing downtime.

[0072] The quick closing time of the piston in the present disclosure improves the accuracy of fluid batches delivered into the tank. The fail-safe closing mechanism ensures that the valve remains closed during mechanical or electrical failures, preventing uncontrolled fluid flow. The trim design significantly reduces the pressure acting directly on the piston, contributing to prolonged valve life and reduced wear. The reverse flow of fluid and the trim design result in an improved responsiveness of the piston to different conditions, enhancing overall operational efficiency. In addition, as illustrated in an embodiment of the present disclosure, in this improved design even if the piston O-ring fails the fluid will not leak to downstream and that will help to eliminate the risk of over flooding in a tank.

[0073] Fig. 4a illustrates a digital control valve (DCV) system (100) in accordance with an embodiment of the present disclosure. As illustrated, the DCV (100) comprises a piston assembly (400) integrated into the cylindrical valve chamber (120). The assembly (400) includes innovative trim design features aimed at precise fluid flow control, improved durability, and fail-safe operation. Fig. 4b depicts the detailed construction of the piston assembly (400) with a dampening mechanism, highlighting key components such as a cylindrical cover with a slot (402), slot point or edge of the slot (404), O-ring (408), gap (406),base ring (410), and annular sealing rings (310). The dampening mechanism in the digital control valve (DCV) system (100) ensures opening or closing of valve by regulating the movement of the valve at a controller flow rate compensating for varying pressure condition.

[0074] The piston assembly (400) comprises a body section (308) and is centrally housed within the cylindrical valve chamber (120). The outer surface of the piston (302) is provided with the slot (402) within the cylindrical cover, which is specifically dimensioned to securely seat an O-ring (408). The O-ring (408) is positioned at an operational distance from the edge of the slot or slot point (404), ensuring that it provides effective cushioning during the rampdown of the piston (302). The slot as shown in Fig. 4b ensures that the O-ring (408) remains firmly seated even under high-pressure conditions, protecting the piston (302) from mechanical shocks. The gap (406), as shown in Fig. 4b, is formed between the outer surface of the piston (302) and the surrounding cylindrical cover with the slot (402). This gap (406) is precisely calibrated to allow a minimal, controlled flow of fluid, which plays a critical role in modulating the ramping speed of the piston. The calibrated width of the gap (406) ensures that fluid flow through it is intentional and controlled, preventing sudden closure of the piston (302). This feature enhances operational reliability and reduces wear and tear on the internal components.

[0075] The annular sealing rings (310) are integrated into the body section (308) of the piston (302) and are configured to protrude into the surrounding chamber. These sealing rings (310) serve to redistribute the fluid pressure to an annular area surrounding the piston body. By directing pressure to this annular area, the sealing rings (310) reduce the force acting directly on the bottom portion (306) of the piston (302), minimizing mechanical stress and ensuring balanced pressure distribution. The trim design further includes a base ring (410), within the slot (402), extending underneath the cylindrical cover, which provides structural support to the O-ring (408). This base ring (410) prevents displacement of the O-ring (408) during rampdown and maintains its effectiveness over repeated operational cycles.

[0076] During operation, the piston (302) responds to the differential pressures between upstream pressure (Pl) and downstream pressure (P2). In the open position, when upstream pressure (Pl) exceeds downstream pressure (P2), fluid flows freely through the cylindrical valve chamber (120). Conversely, as downstream pressure (P2) increases — due to the closure of the NC solenoid valve (112) — the differential pressure (P1-P2) decreases, causing the piston (302) to gradually close. In an exemplary embodiment as shown in Fig. 4b, the gap (406)between the piston (302) and the cylindrical cover with the slot (402) allows a controlled amount of fluid to flow through during the ramp-down process. This controlled flow ensures a gradual reduction in the piston's speed, preventing sudden impacts on the piston (302). The O- ring (408) cushions the piston (302), absorbing mechanical shocks and ensuring a smooth closure.

[0077] The controller (122) continuously monitors the fluid flow rate through the gap. If the flow rate decreases beyond a threshold before the piston (302) contacts the O-ring (408), the controller (122) sends a signal to the solenoid valves (110, 112) to adjust the upstream pressure (Pl). This adjustment lifts the piston (302) slightly, preventing sudden ramp-down and ensuring fail-safe operation under varying pressure conditions. In a preferred embodiment as depicted in Fig. 4b of the present disclosure, the downstream pressure or fluid flow rate during piston ramping down is reduced due to open area in the cylindrical cover. In an instance, even when the complete open area in the cylinder is blocked by the piston, the fluid persistently flows at minimal or less flow rate through the gap (406) between the outer surface of the piston (302) & the cylindrical cover with the slot (402) before piston contacts with the O ring (408). At an instance, the controller detects the minimal flowrate of the fluid and sends the signal to solenoid valve (NC) (112) so as to release the piston top chamber pressure or upstream pressure (Pl) which lifts the piston to ramp up and increasing the fluid flowrate again to prevent the sudden ramping down of piston (302).

[0078] The integration of the cylindrical cover with the slot (402), the O-ring (408), and the gap (406) into the trim design provides precise control over the ramping down speed of the piston (302). The calibrated gap (406) allows for controlled fluid flow, reducing ramp-down speed by utilizing 60% reduced force. This feature prevents sudden closure, ensuring seamless operation even during mechanical or electrical failures. The protruded annular sealing rings (310) direct fluid pressure to the annular area at the body section (308), reducing the direct pressure on the piston’s bottom portion (306) by approximately 30%. This pressure redistribution decreases the force required for valve closure, enhancing operational efficiency and reducing wear on the piston (302). The O-ring (408) provides cushioning during rampdown, protecting the piston (302) from mechanical shocks and prolonging its service life. The combined functionality of the slot (402), O-ring (408), and calibrated gap (406) minimizes the risk of uncontrolled fluid flow, ensuring reliable operation in high-pressure environments.

[0079] Fig. 5 illustrates Digital Control Valve (DCV) system (100) integrated with a hydraulic dampening assembly (500) in accordance with the present disclosure, designed to regulate the movement of the piston (302) during ramp-up and ramp-down operations. In the dampening mechanism, as illustrated in Fig. 5, the hydraulic dampening assembly (500) is situated within the cylindrical valve chamber (120) and comprises three interconnected cavities: the upper cavity (502), the middle cavity (504), and the lower cavity (506). These cavities are interconnected through a series of hydraulic passages and operate synergistically to balance fluid pressure during valve operation.

[0080] The upper cavity (502) is configured with smaller orifices (508) that restrict the flow of fluid during the upward movement of the piston (302). These smaller orifices (508) reduce sudden pressure surges, ensuring a controlled ramp-up operation and preventing abrupt acceleration of the piston. The middle cavity (504), located between the upper cavity (502) and lower cavity (506), is larger in area and incorporates bigger holes (510) in hydraulic pipes. These bigger holes (510) are designed to increase the rate of fluid evacuation during the downward movement of the piston, facilitating rapid fluid transfer to the upper cavity and reducing pressure within the middle cavity (504). Further, as shown in Fig. 5, a side walls (514) surrounding the middle cavity (504), the side walls (514) comprising one or more orifices to control fluid flow between the middle cavity (504) and adjacent cavities. The lower cavity (506) provides additional fluid pathways and contributes to the overall fluid dynamics of the system.

[0081] The hydraulic passages connecting the upper, middle, and lower cavities (502, 504, 506) are precisely engineered to modulate fluid flow during both ramp-up and ramp-down operations. During ramp-up, fluid enters the upper cavity (502) through the smaller orifices (508), which restrict the fluid flow and ensure that the upward movement of the piston (302) occurs gradually, preventing abrupt or uncontrolled acceleration. Conversely, during rampdown, fluid flows from the middle cavity (504) into the upper cavity (502) through the hydraulic passages. The bigger holes (510) in the hydraulic pipes within the middle cavity (504) enable rapid evacuation of fluid, while the smaller orifices (508) in the upper cavity (502) regulate the flow entering it. This controlled evacuation reduces the ramp-down speed of the piston, ensuring smooth closure without abrupt movements.

[0082] A check valve (512) is strategically positioned within the middle cavity (504) to facilitate controlled fluid transfer between the middle cavity (504) and adjacent cavities. The check valve (512) allows unidirectional fluid flow, preventing backflow and maintaining pressure stability across the cavities. This feature ensures that the piston (302) operates reliably, even under varying pressure conditions or during mechanical or electrical failures.

[0083] The hydraulic dampening mechanism provides several technical advantages. By incorporating smaller orifices (508) in the upper cavity (502), the system effectively stabilizes the piston during ramp-up operations, minimizing pressure fluctuations and ensuring a controlled increase in pressure. The bigger holes (510) in the middle cavity (504) facilitate rapid fluid evacuation, reducing the descent speed of the piston (302) by up to 60%, as claimed. In accordance with an embodiment of the present disclosure as shown in Fig. 5, the digital control valve prevents sudden closure of the piston (302) during ramp-down, contributing to smoother operation and enhanced system reliability. The check valve (512) further enhances stability by enabling controlled fluid transfer and maintaining unidirectional flow, ensuring that the piston (302) closes in a fail-safe manner during mechanical or electrical failures.

[0084] Moreover, the hydraulic dampening mechanism redistributes fluid pressure to the annular area surrounding the piston (302), reducing the direct pressure acting on the valve (302). This redistribution minimizes mechanical stress on the piston (302), prolonging its service life and reducing maintenance requirements. The system’s ability to modulate fluid dynamics and pressure distribution results in improved efficiency, faster responsiveness, and precise control of the piston's movement.

[0085] The hydraulic dampening mechanism as depicted in Fig. 5 in the DCV system (100) enables precise control over the movement of the piston (302). By integrating distinct cavities with specifically configured smaller orifices (508), bigger holes (510), and a check valve (512), the system ensures controlled fluid flow and pressure distribution during ramp-up and rampdown operations.

[0086] Any combination of the above features and functionalities may be used in accordance with one or more embodiments. In the foregoing specification, embodiments have been described with reference to numerous specific details that may vary from implementation toimplementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.

Claims

WE CLAIM:

1. A digital control valve system (100) for controlling fluid flow, comprising: a cylindrical valve chamber (120); a piston (302) housed within the cylindrical valve chamber (120), the piston (302) having: a body section (308), and an annular sealing ring (310) protruded to direct pressure at an annular area towards the body section (308); a plurality of solenoid valves (110, 112), including: a normally open (NO) solenoid valve (110) connecting the valve chamber (120) to an upstream pressure (Pl); a normally closed (NC) solenoid valve (112) connecting the valve chamber (120) to a downstream pressure (P2); an electrical controller (122) configured to selectively energize and de-energize the solenoid valves (110, 112) to create differential pressure in the valve chamber (120) for actuating the opening and closing of the piston (302); and at least one dampening mechanism within the cylindrical valve chamber (120) for regulating a movement of the piston (302); wherein during the upstream pressure (Pl), the piston (302) is configured to direct fluid flow pressure onto the annular area of the protruded annular sealing ring (310) to distribute pressure to a larger surface area of the piston (302).

2. The digital control valve system (100) as claimed in claim 1, wherein the piston (302) seated with an O-ring (408) positioned above the annular area, wherein the assembly of the piston with the O-ring creates sealing pressure during closing of the DCV (100) at higher differential pressure across the piston.

3. The digital control valve system (100) as claimed in claim 1, comprising: a manifold assembly (214) housing a plurality of auto-tune valves (ATV), wherein the manifold assembly (214) is positioned at periphery of the digital control valve system, and each auto-tune valve (ATV) (200) comprises: a tapered valve stem with a slender, tapered point incorporated in holes (208) at an end of a valve stem, serving as a throttle valve;a plurality of springs (204) housed in a C-ring (206) structure for controlling needlelike structures, poppets (210), and fluid flow; and a poppet (210) integrated with strategically positioned apertures for enabling selfadjustment of the valve stem position in response to varying upstream (Pl) and downstream pressure (P2) conditions, wherein the poppet (210) dynamically adjusts a size of an orifice (202) to provide automated tuning of fluid flow.

4. The digital control valve system (100) as claimed in claim 3, wherein the manifold assembly (214) houses at least two auto-tune valves positioned symmetrically for controlled fluid flow.

5. The digital control valve system (100) as claimed in claim 3, wherein the manifold assembly (214) has a screw-in cartridge valve construction for facilitating maintenance and inspection of the auto-tune valve (200) without disassembling an entire digital control valve.

6. The digital control valve system (100) as claimed in claim 3, wherein the poppets (210) are configured to self-determine in response to varying upstream or downstream pressure (Pl, P2) fluctuations and move laterally within the ATV (200) to adjust the size of the orifice (202).

7. The digital control valve system (100) as claimed in claim 1, wherein at least one dampening mechanism may be a hydraulic dampening assembly (500).

8. The digital control valve system (100) as claimed in claim 7, wherein the hydraulic dampening assembly (500) is integrated within the piston chamber (120) and comprises a cavity formed within the piston (302), the cavity including: a middle cavity (504) positioned between an upper cavity (502) and a lower cavity (506); a side wall (514) surrounding the middle cavity (504), the side wall (514) comprising one or more orifices to control fluid flow between the middle cavity (504) and adjacent cavities; and wherein the cavities (502, 504, 506) are configured to enable controlled fluid transfer during movement of the piston (302).

9. The digital control valve system (100) as claimed in claim 7, wherein the hydraulic dampening assembly (500) comprises: a plurality of hydraulic passages between the upper cavity (502), middle cavity (504), and lower cavity (506); the hydraulic passages comprise:(a) smaller orifices (508) in the upper cavity (502) for restricting the fluid flow during upward movement of the piston (302) to reduce sudden pressure fluctuations;(b) larger orifices in the middle cavity (504) to accelerate fluid evacuation from the middle cavity (504) with large orifices to the upper cavity (502) with small orifices (508) during downward movement of the piston (302); and wherein the hydraulic passages are configured to direct fluid between the cavities to stabilize the piston (302) during ramp-up and ramp-down operations.

10. The digital control valve system (100) as claimed in claim 9, wherein the fluid flows from the middle cavity (504) with larger orifices to the upper cavity (502) with smaller orifices (508) during ramping down of the piston (302).

11. The digital control valve system (100) as claimed in claim 9, wherein the hydraulic dampening assembly (500) comprises: the middle cavity (504) with a larger area connected to the upper cavity (502) through hydraulic pipes, the hydraulic pipes incorporating a plurality of bigger holes (510) configured to increase a speed of fluid flow from the middle cavity (504) to the upper cavity (502), wherein an increased fluid flow through each of the holes (510) in the hydraulic pipes accelerates the fluid evacuation of fluid from the middle cavity (504) and reduces the pressure in the middle cavity (504); and a reduced ramp-down speed of the piston (302) to prevent sudden closure of the piston (302), ensuring smoother operation of the digital control valve.

12. The digital control valve system (100) as claimed in claim 11, wherein the hydraulic dampening assembly (500) includes a check valve (512) with an orifice in the middle cavity (504) to facilitate controlled fluid transfer between the middle cavity (504) and adjacent cavities during operation.

13. The digital control valve system (100) as claimed in claim 1, wherein the at least one dampening mechanism comprises a trim design of the piston (302), the trim design including:a cylindrical cover with a slot (402) at an outer surface of the piston (302), wherein the slot (402) is seated with the O-ring (408) positioned at an operational distance from an edge (404) of the slot and the O-ring (408) being configured to cushion the piston (302) during rampdown.

14. The digital control valve system (100) as claimed in claim 13, wherein a gap (406) is provided between the piston (302) and the cylindrical cover with the slot (402) surrounding the piston (302) has a calibrated width and height at the edge (404) of the slot (402) tailored to allow intentional minimal fluid flow for controlled ramping down speed of the piston (302).

15. The digital control valve system (100) as claimed in claim 1, wherein the controller (122) detects reduced flow rates through the gap (406) before the piston (302) contacts the O- ring (408) and sends a signal to the solenoid valves (110, 112) to increase upstream pressure (Pl) and lift the piston (302) to prevent sudden ramping down of the piston (302).

16. An auto-tune valve (ATV) (200) for a digital control valve system, comprising: a manifold assembly (214) housing a plurality of auto-tune valves (ATV), the manifold assembly (214) being linearly constructed and positioned at periphery of the digital control valve system, enabling independent access and maintenance of each of the plurality of autotune valves (ATV) without disassembling the entire digital control valve system; each of the plurality of auto-tune valves (ATV) (200) comprises: a tapered valve stem with a slender, tapered point incorporated in holes configured to adjust an orifice (202); a poppet (210) integrated with strategically positioned apertures for enabling selfadjustment of the valve stem position in response to varying upstream pressure (Pl) and downstream pressure (P2) conditions; a spring mechanism housed in a C-ring (206) structure configured to exert controlled force on the poppet (210) for precise regulation of fluid flow; a conduit interface between the manifold assembly (214) and the digital control valve system for fluid communication; and wherein the plurality of auto-tune valves (ATVs) dynamically modulates the fluid flow by adjusting the orifice (202) size in a response to differential pressure conditions and provides automated tuning of the fluid flow without manual intervention.

17. The auto-tune valve (200) as claimed in claim 16, wherein the manifold assembly (214) is secured by screws (212) and is configured for independent attachment to the digital control valve system.

18. The auto-tune valve (200) as claimed in claim 16, wherein the manifold assembly (214) includes a screw-in cartridge valve construction to facilitate maintenance and inspection of the plurality of auto-tune valves without disassembling the entire digital control valve system.

19. The auto-tune valve (200) as claimed in claim 16, wherein each of the auto-tune valve (ATV) (200) is configured to dynamically adjust the orifice (202) size by lateral movement of the poppet (210) in the response to differential pressure conditions between the upstream pressure (Pl) and the downstream pressure (P2).

20. A piston assembly (400) for a digital control valve, comprising: a cylindrical valve chamber (120) housing a piston (302), wherein the piston (302) comprises: a body section (308), and annular sealing rings (310) protruded to direct pressure at an annular area towards the body section (308), a trim design incorporating: a cylindrical cover with a slot (402) seated with an O-ring (408), the slot (402) having a base ring (410) configured to protect the piston (302) during ramp-down operations; a gap (406) provided between the piston (302) and the cylindrical cover surrounding the piston (302), the gap (406) configured to allow controlled fluid flow through the slot (402) for reducing a ramping speed of the piston (302); wherein the piston (302) operates to open or close based on upstream pressure (Pl) and downstream pressure (P2) differentials within the cylindrical valve chamber (120); and wherein during upstream pressure, the piston (302) is configured to direct fluid flow onto the annular area to distribute pressure to a larger surface area of the piston (302).

21. The piston assembly (400) as claimed in claim 20, wherein the protrusion at a head section of the piston (302) are configured to direct fluid flow into the annular area for controlled pressure distribution.

22. The piston assembly (400) as claimed in claim 20, wherein a pressure-balancing space is dimensioned to delay sudden valve closure during high upstream pressure (Pl) conditions.

23. The piston assembly (400) as claimed in claim 20, wherein a fluid pressure in the piston (302) is redirected to the annular area in the body section (308) of the piston (302), reducing the pressure on the piston (308) significantly decreasing a time required for the main valve (118) to close.

24. The piston assembly (400) as claimed in claim 20, wherein the piston (302) closes with high force due to higher pressure differential across the piston (302).

25. The digital control valve system (100) as claimed in claim 1, wherein the system is configured to automatically close a main valve (118) in an event of a mechanical failure, including spring or Piston O-ring failure; or in an event of an electrical failure, including complete terminal power outage or cessation of pump operation.

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