Cable Tension Estimation System for Cable-Stayed Structures Using FPGA and Accelerometer Based on the Flat Taut String Method
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Abstract
Abstract—The One of critical aspects of Structural Health Monitoring (SHM) systems is cable tension estimation, particularly in cable-stayed structures. This study compares two tension estimation approaches: a direct method using a load cell and an indirect method based on vibration response analysis through an FPGA–accelerometer system. The developed system utilizes an Altera DE0-Nano FPGA board to acquire acceleration signals from the ADXL345 sensor via SPI, and simultaneously transmits the data to a host computer via UART. The data is collected in real time and externally analyzed using the Welch Fast Fourier Transform (FFT) algorithm. The extracted fundamental frequency is then applied to the flat taut string theory to estimate cable tension. The experiment was conducted on an isolated test rig under various tension conditions, with ground truth measurements obtained from a calibrated load cell. The results indicate that the system offers reliable estimation performance, especially in the high-tension group, achieving a mean relative error of 6.18% and a coefficient of determination (R²) of 0.963 compared to load cell readings. It also demonstrates good measurement consistency, with an average repeatability error of 4.8%. Despite using the low-cost ADXL345 sensor with a measured average Signal-to-Noise Ratio (SNR) of approximately 25.9 dB, the system exhibits sufficiently high accuracy and reliability. Therefore, the proposed FPGA–accelerometer-based approach is considered a viable, non-invasive, and efficient alternative for cable tension estimation in SHM applications.
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