A theoretical method is proposed in this paper to calculate the unit curve of gear integrated error (GIE). The calculated GIE unit curve includes the quasi-static transmission error (TE) curves of the approach stage, the involute stage, and the recession stage of the ZI worm and helical gear transmission. The misalignments between the two axes of the worm and gear, as well as the modifications or errors of the tooth flanks of the gear, are considered in the procedure of calculation. Optimization algorithm is introduced to replace the solving of implicit differential equations of the conventional tooth contact analysis (TCA) method. It is proved that the proposed method is clearer and more convenient than the conventional TCA methods in calculating the GIE unit curve. The correctness and merits of the proposed method are verified by two experiments.

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So far, researches of the meshing performance of vehicles cylindrical gears are quite rare. Testers that can be used to test the gear pair’s performance for vehicles cylindrical gears do not exist. A tester that can be used to test vehicles cylindrical gears paring performance was developed, which fills the gaps of vehicles cylindrical gears meshing performance tester. The maximum diameter of gears measured is 500mm, the maximum spindle speed is 3000r/min and the maximum load torque is 200N.m. The tester can inspect and measure the following items simultaneously, such as the transmission errors, the vibration and noise, the contact pattern, the eccentricity errors and so on. There is gear error analysis function in this tester. In addition, it can meet the quality inspection requirements for the vehicles cylindrical gears with the accuracy of grade 5.

With the development of gears towards high temperature, high pressure, high speed and high stress, gear measurement, in which only the static geometric accuracy is considered, is unable to meet the current application requirements. While, the low precision and single function gear tester constrains the measurement of gear dynamic performance. For the resolution of this problem, based on the principle of gear system dynamics and several precision mechanical design techniques, a gear dynamic testing machine has been developed, providing new instruments for gear testing. On the basis of research of the principle of dynamic performance test, the primary measurement items of the testing machine have been determined. The measuring principles of each item and the driving and loading form of the testing machine have been examined. The measurement and control system of the testing machine and its corresponding software have been developed. The instrument can not only obtain the static precision index of the gear, but also obtain the dynamic performance index of the gear in variable working conditions. According to the actual test, the uncertainty of instrument is 3.8 μm and the external disturbance caused by the shaft vibration is less than 0.6 μm, which can meet the 5–6 grade precision gear testing requirement.