Purpose The six-component rotor balance is a core force-measuring component for evaluating rotor mechanical properties and advancing helicopter aerodynamics research. To meet the specific aerodynamic design requirements of a certain helicopter model, this study aims to develop a high-performance piezoelectric six-component rotor balance that addresses the demands of high rigidity and dynamic response in helicopter rotor tests, and to systematically verify its measurement reliability under complex working conditions. Design/methodology/approach This paper adopts a theoretical modeling–finite element simulation–experimental validation integrated approach. First, based on the point hypothesis and rigid body hypothesis, the mechanical model of the piezoelectric rotor balance was simplified to clarify its fundamental force-measuring principle and force transmission mechanism. A three-component piezoelectric sensor (TPS), designed and fabricated using the piezoelectric effect, was used as the core measurement unit. A 3D model of the balance was established for finite element analysis (FEA), focusing on static performance under full load, natural frequency characteristics and force-measuring stability across different environmental temperatures. Subsequently, a dedicated six-dimensional force static calibration test bench was constructed to conduct static performance calibration. Furthermore, composite loading tests and temperature variation tests (223–323 K) were carried out to validate the balance’s performance under simulated complex rotor test conditions. Findings FEA results demonstrate that the first-order natural frequency of the developed balance reaches 1,072.3 Hz, confirming its excellent dynamic performance, and its force-measuring characteristics exhibit high stability with temperature variations. Static calibration tests show that the balance meets all test requirements, with a maximum linear error of only 0.55%. Under composite loading conditions, the balance maintains high measurement accuracy, with a maximum deviation of 1.2%. Temperature variation tests verify the FEA results: the maximum measurement error is 0.31% at 223 K and 0.17% at 323 K. Collectively, the balance achieves stable working status and reliable force-measuring performance within the temperature range of 223–323 K. Research limitations/implications This study contributes a novel piezoelectric six-component rotor balance tailored specifically for helicopter aerodynamic experiments, which features superior rigidity and dynamic performance compared to conventional alternatives. The originality lies in the design of a TPS as the core measurement module, combined with a rigorous theoretical and experimental framework that validates the balance’s performance under extreme temperature and composite loading conditions. The proposed balance fills the gap in high-dynamic-performance force-measuring devices for helicopter rotor tests and provides a reliable experimental basis for the aerodynamic design and optimization of the target helicopter model. Practical implications The helicopter piezoelectric rotor balance can be directly applied to helicopter rotor test benches, meeting high-precision, high-stability force-measuring needs, reducing test equipment maintenance costs and providing references for high-precision force-measuring device development in aerospace, with engineering transformation and commercial potential. Social implications It helps improve helicopter aerodynamic design and safety, indirectly ensuring flight safety, promoting technological upgrading in the aerospace industry, supporting technical innovation in related fields and driving the development of high-precision sensor and test equipment industrial chains. Originality/value A six-component piezoelectric helicopter rotor balance test system is proposed. The effect of ambient temperature on the performance of rotor balance is studied. The helicopter rotor balance can work stably under compound loading conditions. Six-way static calibration test of rotor balance is carried out on the test system. Nonlinear/repeatability error and interphase interference all meet test requirements.
Li et al. (Fri,) studied this question.