In order to improve the reliability and real-time of the control system of aero-engine, an intelligent fault-tolerant control system based on the online sequential extreme learning machine (OS-ELM) is proposed against the sensor faults. This system can realize the online fault diagnosis and signal reconstruction without a system model. And while considering the traditional PID control robustness and poor anti-interference ability and other shortcomings, an improved global fast non-singular terminal sliding mode control method is used to obtain better control effects, effectively solve the uncertainty problem in aero-engine, and give full play to aero-engine performance. To verify the feasibility and effectiveness of this system based on the above method, a turbofan engine is taken as the research object and semi-physical simulation experiments on fault-tolerant control are conducted on a semi-physical simulation test platform. Results show that the controller of this system can safely and reliably control the aero-engine without losing its control performance under the circumstance that there are faults in engine sensors. The purpose of fault-tolerant control is reached.