Structure and performance of color blended rotor spun yarn produced by a novel frame with asynchronous feed rollers

This paper introduces a new and flexible spinning method that is modified on a rotor spinning machine. The modification is implemented by a novel mechanical system specially designed to incorporate three separate feed rollers side by side and controlled by servo motors with programmable logic controller (PLC). Using this new method, yarn structure parameters including linear density and blend ratio can be controlled and realized by asynchronous drafted slivers. Sixty-six types of color blended yarns were produced by controlling blending percentages of three basic colored slivers (magenta, yellow, and cyan) by changing the feeding speeds of the slivers respectively with constant yarn linear density and color. Surface morphologies, blending effects, and performances of the yarns were tested and analyzed. In addition, fancy yarns including slub yarn, period melange yarn, gradient melange yarn, and color pointed melange yarn were produced and their longitudinal morphologies were taken. The results demonstrated spinning feasibility and product variety of the three channeled rotor spun process