**Abstract:** The first-generation control valves suffer from three major issues: bulkiness, incomplete functionality, and poor reliability. As a breakthrough in new product development, the "full-function ultra-light control valve" has been introduced. Upon its release, it received high praise and recognition from users and design institutes. As a next-generation product, it is expected to gradually replace current leading models and become the mainstream of control valves in the coming century. **Keywords:** full-function; ultra-light; control valve --- **1. The History of Control Valves** Since the 1960s, nine categories of control valves—single-seat, double-seat, diaphragm, angle, butterfly, ball, three-way, sleeve, and eccentric rotary valves—were developed. However, for the next thirty years, there were no significant breakthroughs or upgrades. Improvements were limited to refining existing designs. A notable example was the CV3000 in the 1970s and the domestic small single-seat valve and sleeve valve in the 1980s, which reduced weight and height by about 30% but did not achieve any functional or reliability breakthroughs. Despite this, the traditional single-seat, double-seat, and sleeve valves remain dominant today, which is increasingly incompatible with the rapid advancement of automation technology. Therefore, the valve industry urgently needs a new generation of products. **2. Major Problems of Current Leading Products** To identify the direction for innovation, we first analyzed the problems of existing control valves. In 1997, a comprehensive survey revealed nine key issues: excessive complexity (33.13%), variety causing confusion (67.11%), leakage (42.15%), frequent clogging and slow action (25.18%), short lifespan (13.17%), insufficient actuation force (9.16%), low flow coefficient and narrow adjustment range (5.12% and 4.13%), and vibration, noise, and oscillation (11.7%). These issues are linked to both design flaws and manufacturing quality, but the core problems lie in three areas: size, functionality, and reliability. **2.1 Bulky Design** Control valves can weigh from tens to thousands of kilograms, making transportation, installation, and maintenance cumbersome and costly. **2.2 Incomplete Functionality** The coexistence of multiple valve types leads to redundancy and complicates selection, maintenance, and spare parts management. **2.3 Poor Reliability** Low reliability results in common problems such as leakage, sticking, and slow response, which hinder system performance and increase maintenance costs. **3. Breakthrough Direction for New Products** Based on these challenges, we identified three key areas for improvement in the next-generation control valve: - **Weight Reduction:** Reduce the weight of single-seat, double-seat, and sleeve valves by 60%–80%, and make them even lighter than fine valves by 30%–50%. - **Full-Functionality:** Replace multiple incomplete functions with one multi-functional or fully featured valve to simplify specifications and operations. - **Reliability Improvement:** Address each reliability issue step by step to ensure stable and long-lasting performance. **4. The Birth of a New Control Valve – Full-Function Ultra-Light Valve** After extensive research and development over two years, the full-function ultra-light valve was born, solving the three major problems of old products: bulkiness, incompleteness, and poor reliability. It features three key characteristics: **4.1 Ultra-Light Weight** Compared to traditional single-seat, double-seat, and sleeve valves, the new valve reduces weight by 60%–70% (pneumatic) and 70%–80% (electric). Its compact design makes it easy to transport, install, and maintain. **4.2 Full-Functionality** The valve integrates multiple functions into one, including flow regulation, shut-off, pressure resistance, anti-blocking, corrosion resistance, and more. It outperforms traditional valves in all aspects, as shown in Table 3. **4.3 High Reliability** Key improvements include: - Stiff stem and wear-resistant packing for longer life. - Hard-seal core and seat with alloy surfacing for superior sealing. - Reliable electric actuators with up to 10 years of maintenance-free operation. - Pneumatic actuators with rack-and-pinion design for smooth and accurate movement. - Sufficient torque to overcome pressure and friction. - Streamlined flow path to prevent blockage. - Reduced seat friction to extend service life. **4.4 Performance Specifications** - Model: Pneumatic ZSRH, Electric (Electronic) ZDRH - Nominal Diameter: DN20–400 - Nominal Pressure: PN1.6–32 - Flow Characteristics: Approximate logarithmic or linear - Adjustable Range: 100–200 - Leakage Rate: 1×10⁻⁶ to 1×10⁻⁷ - Allowable Pressure Difference: ≤PN - Operating Temperature: -60°C to +600°C **4.5 Practical Application and Significance** Since its launch, the full-function ultra-light valve has been widely adopted by over ten manufacturers, with thousands of units produced. Its ultra-light design, full functionality, and high reliability have drawn attention from both users and design institutes. This innovation marks four major breakthroughs in control valve history: weight reduction, functional enhancement, reliability improvement, and the breakthrough of electric valve applications. It will gradually replace traditional valves and become the mainstream of the control valve industry in the new century. This achievement represents a significant contribution to the development of control valves in China.

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