To address the challenge of obtaining process noise covariance in Kalman filters for structural response reconstruction, a two-stage optimal Q estimation (TOQE) algorithm was proposed. Under a fixed window length, a minimization error function concerning Q was established, and the search interval was derived based on the innovation theory. A one-dimensional two-stage search strategy was employed to accelerate the search for the process noise covariance Q. The Savitzky-Golay (SG) smoothing algorithm was used to smooth the estimated process noise covariance between windows, achieving the optimal process noise covariance estimation. Finally, the Kalman filters was used to reconstruct the structural response. The effectiveness of the algorithm was validated through simulations of a vertical axis wind turbine and experiments on a cantilever beam. The reconstructed acceleration response was applied to identify the excitation of the cantilever beam structure under L1/L2 regularization. The results show that compared to the traditional optimal Q estimation (OQE) algorithm for response reconstruction, the TOQE algorithm can determine the search interval for one-dimensional search under 5%, 10%, and 15% measurement noise, respectively, avoiding the subjective selection of OQE search interval and achieving optimal process noise covariance estimation. The search efficiency was improved by 50%~60%. Under different accuracy evaluation standards, the response reconstruction error of the TOQE algorithm is reduced, and the reconstructed acceleration response can better identify the external excitation of the cantilever beam structure. The TOQE algorithm demonstrates good real-time performance and robustness.
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