CN114335619B - Fault monitoring and processing method and system for fuel cell air inlet flow sensor and vehicle - Google Patents
Fault monitoring and processing method and system for fuel cell air inlet flow sensor and vehicle Download PDFInfo
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- CN114335619B CN114335619B CN202111661548.7A CN202111661548A CN114335619B CN 114335619 B CN114335619 B CN 114335619B CN 202111661548 A CN202111661548 A CN 202111661548A CN 114335619 B CN114335619 B CN 114335619B
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Abstract
The invention discloses a fault monitoring and processing method and system for an air inlet flow sensor of a fuel cell and a vehicle, wherein the method comprises the following steps: powering up and finishing initialization; detecting whether the air inlet temperature pressure sensor, the air compressor and the back pressure valve have faults or not and whether an air pipeline has falling faults or not, if so, detecting whether the flow sensor has faults or not; if yes, prompting the fault, and adopting the estimated air inlet flow Qe to replace the measured flow of the flow sensor in the follow-up operation until the fault is recovered. By the fault monitoring and processing method for the fuel cell air inlet flow sensor, the working state of the flow sensor is monitored in real time, and potential safety hazards of the fuel cell caused by the fault of the flow sensor can be eliminated.
Description
Technical Field
The present invention relates to the field of fuel cells, and in particular, to a method and a system for monitoring and processing faults of an air intake flow sensor of a fuel cell, and a vehicle.
Background
The fuel cell air system is mainly used for supplying air to the cathode side of the fuel cell and mainly comprises an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, corresponding air pipelines, sensors and the like, and the structural schematic diagram of the fuel cell air system is shown in figure 1. In general, the air intake flow required by the control of the Fuel Cell Controller (FCCU) comes from the measured flow of the flow sensor behind the air filter, if the flow sensor fails, the fuel cell cannot normally operate, if the flow sensor fails during driving, such as signal interruption of the flow sensor, the flow sensor will directly cause major potential safety hazards such as power interruption, etc., therefore, it is necessary to develop a fault monitoring processing method for the air intake flow sensor of the fuel cell, which can monitor the working state of the flow sensor and replace the flow sensor to continue to operate immediately after the flow sensor fails.
Disclosure of Invention
The invention aims to provide a fault monitoring and processing method and system for an air inlet flow sensor of a fuel cell, and a vehicle, wherein the working state of the flow sensor is monitored in real time, so that potential safety hazards of the fuel cell caused by the fault of the flow sensor can be eliminated.
In order to achieve the above object, the present invention provides a method for monitoring and processing faults of an intake air flow sensor of a fuel cell, comprising the steps of:
(S1) powering up and finishing initialization;
(S2) detecting whether the air inlet temperature pressure sensor, the air compressor and the back pressure valve are all fault-free and whether the air pipeline is free of falling faults, if so, turning to an execution step (S3);
(S3) detecting whether the flow sensor is malfunctioning; if yes, go to execute step (S7); otherwise, go to execute step (S4);
(S4) starting the fuel cell to operate, and monitoring the actual measurement flow Qa of the flow sensor in real time;
(S5) calculating an estimated air intake flow Qe,
(S6) judging whether the absolute value Qa-Qe is smaller than a calibration threshold value, if so, enabling the flow sensor to work normally, and ending the flow; otherwise, the measurement error of the flow sensor is overlarge, and the step (S7) is executed;
and (S7) prompting the fault, and adopting the estimated air inlet flow Qe to replace the measured flow of the flow sensor in the follow-up operation until the fault is recovered.
Further, in step (S2), if not, step (S2) is continued.
Further, the calculation formula of the estimated air intake flow Qe is as follows:
wherein: qe represents the estimated air intake flow; v represents the volume of an air inlet cavity of the electric pile; p represents the actual measurement of the air inlet pressure of the air inlet temperature pressure sensor; ps represents saturated steam pressure at different temperatures, and is obtained by inquiring a temperature-saturated steam pressure relation table; r represents a gas constant; ma represents the molar mass of dry air; t represents the actual measurement of the air-in temperature pressure sensor; n represents the actual measured rotating speed of the air compressor; x represents the actual measurement of the opening of the back pressure valve by the back pressure valve position sensor; h (n, x) represents relative humidity related to the rotating speed n of the air compressor and the opening x of the back pressure valve, the measured value of the internal humidity of the electric pile is filled into a relative humidity meter, and the relative humidity is obtained by positioning and interpolating the measured rotating speed n of the air compressor and the opening x of the back pressure valve; the correction coefficients related to the air compressor rotating speed n and the back pressure valve opening x are represented, and the correction coefficients are obtained by inquiring a calibrated air compressor rotating speed-back pressure valve opening-correction coefficient relation table.
Further, the calibration steps of the air compressor rotating speed-back pressure valve opening-correction coefficient relation table are as follows:
(A1) Setting an air compressor rotating speed-back pressure valve opening-correction coefficient relation table, and setting m different air compressor rotating speed values n 1 、n 2 、···、n i 、···、n m And m different back pressure valve opening values x 1 、x 2 、···、x j 、···、x m The rotation speed values of m different air compressors and the opening values of m different back pressure valves form m operating points (n i ,x j ) And setting m x m operating points (n i ,x j ) The corresponding correction coefficientAre all equal to 1;
(A2) Selecting a first operating point (n i ,x j );
(A3) Acquiring relative humidity H (n, x), recording actual measurement air inlet pressure P, actual measurement air inlet temperature T, actual measurement air compressor rotating speed n, actual measurement air inlet flow Qa and actual measurement back pressure valve opening x, and calculating estimated air inlet flow Qe under the working condition point;
(A4) Comparing whether the difference between Qe and Qa is within a preset range;
if yes, go to execute step (A5);
otherwise, resetting the correction coefficient under the working condition pointIs transferred to the execution of step (A3);
(A5) Recording correction coefficient under the working condition pointTurning to an execution step (S6);
(S6) whether all working condition points are calibrated is judged, if yes, the calibration is finished by the relation table of the rotating speed of the air compressor, the opening degree of the back pressure valve and the correction coefficient; otherwise, selecting the next working point (n i ,x j ) Go to step (A3).
Further, whether the difference between the comparison Qe and Qa is within a preset range or not specifically executes the following steps:
judging whether the value of Qe-Qa/Qa is smaller than a preset threshold value.
Further, the preset threshold is equal to 3%.
Further, the detecting whether the air inlet temperature pressure sensor, the air compressor and the back pressure valve have no faults and whether the air pipeline has no falling faults, and specifically executing the following steps:
(S01) detecting whether the air-in temperature and pressure sensor has no fault, if so, turning to an execution step (S02); otherwise, continuing to execute the step (S01);
(S02) detecting whether the air compressor has no fault, if so, turning to an execution step (S03); otherwise, go to execute step (S01);
(S03) detecting whether the back pressure valve has no fault, if so, turning to an execution step (S04); otherwise, go to execute step (S01);
(S04) detecting whether the air pipeline has no falling fault, if so, turning to an execution step (S3), otherwise, turning to an execution step (S01).
The invention also provides a fault monitoring and processing system of the fuel cell air inlet flow sensor, which comprises the following steps:
the fuel cell air system comprises a pile, an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, an air inlet temperature pressure sensor and a flow sensor, wherein the air filter, the air compressor, the intercooler, the humidifier and the air inlet end of the pile are sequentially connected, the air outlet end of the pile, the humidifier and the back pressure valve are sequentially connected, the flow sensor is arranged on a pipeline between the air filter and the air compressor, and the air inlet temperature pressure sensor is arranged at the air inlet end of the pile;
the fault detection module is used for detecting and sending whether the air inlet temperature pressure sensor, the air compressor, the back pressure valve and the air pipeline have faults or not;
the fuel cell controller is used for receiving the actually measured air inlet pressure and temperature, the rotating speed of the air compressor, the air inlet flow, the opening degree of the back pressure valve and fault signals, and carrying out corresponding calculation and logic processing;
the fault detection module, the air compressor, the back pressure valve, the air inlet temperature and pressure sensor and the flow sensor are all connected with the fuel cell controller, and the fuel cell air inlet flow sensor fault monitoring processing system is configured to execute the steps of the fuel cell air inlet flow sensor fault monitoring processing method.
The fuel cell air system further includes a humidity sensor coupled to the fuel cell controller.
The invention also provides a vehicle comprising the fault monitoring and processing system of the fuel cell air inlet flow sensor.
Compared with the prior art, the invention has the following advantages:
the fuel cell air inlet flow sensor fault monitoring processing method, the system and the vehicle can monitor the working state of the flow sensor in real time based on the redundant design of the flow sensor, and replace the flow sensor to work until the fault is repaired after the flow sensor breaks down, thereby eliminating the potential safety hazard of the fuel cell caused by the fault of the flow sensor.
Drawings
FIG. 1 is a schematic diagram of a fuel cell air system;
FIG. 2 is a flow chart of a method of fault monitoring and handling of a fuel cell inlet flow sensor according to the present invention;
FIG. 3 shows the correction factors of the present invention Is a flow chart of the calibration of (a);
fig. 4 is a schematic diagram of a fuel cell intake air flow sensor fault monitoring and handling system according to the present invention.
In the figure:
1-fuel cell air system, 2-fault detection module, 3-fuel cell controller.
Detailed Description
The following describes the embodiments of the present invention further with reference to the drawings.
Referring to fig. 2, the embodiment discloses a fault monitoring and processing method for an air intake flow sensor of a fuel cell, which includes the steps:
(S1) powering up and finishing initialization;
(S2) detecting whether the air inlet temperature pressure sensor, the air compressor and the back pressure valve are all fault-free and whether the air pipeline is free of falling faults, if so, turning to an execution step (S3); the air line refers to the line between the hollow filter and the back pressure valve in fig. 1.
(S3) detecting whether the flow sensor is malfunctioning; if yes, go to execute step (S7); otherwise, go to execute step (S4);
(S4) starting the fuel cell to operate, and monitoring the actual measurement flow Qa of the flow sensor in real time;
(S5) calculating an estimated air intake flow Qe,
(S6) judging whether the absolute value Qa-Qe is smaller than a calibration threshold value, if so, enabling the flow sensor to work normally, and ending the flow; otherwise, the measurement error of the flow sensor is overlarge, and the step (S7) is executed;
and (S7) prompting the fault, and adopting the estimated air inlet flow Qe to replace the measured flow of the flow sensor in the follow-up operation until the fault is recovered. And in the subsequent operation, adopting the estimated air inlet flow as the replacement flow until the fault is repaired so as to ensure that the fuel cell can continue to operate. The fault may be prompted by illuminating a fault light, or in some embodiments, by voice, text message, or other means, or a combination of prompts, to alert the user to timely check for maintenance.
In the present embodiment, if not in step (S2), step (S2) is continued. If the air inlet temperature and pressure sensor fails, the air compressor fails, the back pressure valve fails or the air pipeline falls off, the flow sensor monitoring function cannot be performed.
In this embodiment, the calculation formula of the estimated air intake flow Qe is as follows:
wherein: qe represents the estimated air intake flow; v represents the volume of an air inlet cavity of the electric pile; p represents the actual measurement of the air inlet pressure of the air inlet temperature pressure sensor; ps represents saturated steam pressure at different temperatures, and is obtained by inquiring a temperature-saturated steam pressure relation table; r represents a gas constant; ma represents the molar mass of dry air; t represents the actual measurement of the air-in temperature pressure sensor; n represents the actual measured rotating speed of the air compressor; x represents the actual measurement of the opening of the back pressure valve by the back pressure valve position sensor; h (n, x) represents relative humidity related to the rotating speed n of the air compressor and the opening x of the back pressure valve, the measured value of the internal humidity of the electric pile is filled into a relative humidity meter, and the relative humidity is obtained by positioning and interpolating the measured rotating speed n of the air compressor and the opening x of the back pressure valve; the correction coefficients related to the air compressor rotating speed n and the back pressure valve opening x are represented, and the correction coefficients are obtained by inquiring a calibrated air compressor rotating speed-back pressure valve opening-correction coefficient relation table.
The temperature-saturated steam pressure relation table is a standard table, can be directly acquired on the internet and is required to be recorded into FCCU software, and the FCCU software can look up a table according to different temperatures to acquire saturated steam pressure at different temperatures during operation.
The humidity sensor is used for measuring the humidity of the inlet position of the fuel cell stack, and the humidity inside the stack is characterized by the humidity of the inlet of the stack because the humidity inside the stack cannot be measured by the sensor.
The humidity sensor is a sensor externally added on the rack, an actual measurement value of the humidity inside the electric pile is measured in the rack and is input into the FCCU software relative humidity meter for interpolation, the meter is related to the rotating speed of the air compressor and the opening of the back pressure valve, and the FCCU can position and then interpolate through the rotating speed and the opening in operation to obtain the relative humidity.
Referring to fig. 3, the calibration steps of the air compressor rotating speed-back pressure valve opening-correction coefficient relation table are as follows:
(A1) Setting an air compressor rotating speed-back pressure valve opening-correction coefficient relation table, and setting m different air compressor rotating speed values n 1 、n 2 、···、n i 、···、n m And m different back pressure valve opening values x 1 、x 2 、···、x j 、···、x m The rotation speed values of m different air compressors and the opening values of m different back pressure valves form m operating points (n i ,x j ) And setting m x m operating points (n i ,x j ) The corresponding correction coefficientAre all equal to 1;
the relation table of the rotational speed of the air compressor, the opening degree of the back pressure valve and the correction coefficient is a two-dimensional table related to the rotational speed of the air compressor and the opening degree of the back pressure valve, for example, as shown in table 1, the rotational speed of the air compressor is an x-axis, and the back pressure is the value of the back pressureThe valve opening is the y axis, and z is the correction coefficient。
TABLE 1
(A2) Selecting a first operating point (n i ,x j ) The method comprises the steps of carrying out a first treatment on the surface of the For example, a first operating point (n i ,x j ) For (n 1, x 1), n1=20000, x1=10 in the above table;
(A3) Acquiring relative humidity H (n, x), recording actual measurement air inlet pressure P, actual measurement air inlet temperature T, actual measurement air compressor rotating speed n, actual measurement air inlet flow Qa and actual measurement back pressure valve opening x, and calculating estimated air inlet flow Qe under the working condition point;
(A4) Comparing whether the difference between Qe and Qa is within a preset range;
if yes, go to execute step (A5);
otherwise, resetting the correction coefficient under the working condition pointIs transferred to the execution of step (A3); for example, the current point (n 1, x 1) is the operating point, the correction factor 1 at (n 1, x 1) is adjusted to 0.9.
(A5) Recording correction coefficient under the working condition pointTurning to an execution step (S6);
(S6) whether all working condition points are calibrated is judged, if yes, the calibration is finished by the relation table of the rotating speed of the air compressor, the opening degree of the back pressure valve and the correction coefficient; otherwise, selecting the next working point (n i ,x j ) Go to step (A3). For example, the previous operating point is (n 1, x 1), and the next operating point is selected according to the selection order (n 1, x 2 ) I.e. n1=20000, x in the table above 2 Operating point=20, and repeating steps (A3) and (A4) until all operating points are calibratedForming; after calibration is completed, recording the correction coefficients of all the recorded working condition points into the FCCU.
In this embodiment, whether the difference between the comparison Qe and Qa is within the preset range or not specifically performs the following steps: judging whether the value of Qe-Qa/Qa is smaller than a preset threshold value. In this embodiment, the preset threshold is equal to 3%. Other values may also be used in certain embodiments, and are not limited herein.
In this embodiment, the detecting whether the air inlet temperature pressure sensor, the air compressor and the back pressure valve have no faults and whether the air pipeline has no falling fault specifically includes the following steps:
(S01) detecting whether the air-in temperature and pressure sensor has no fault, if so, turning to an execution step (S02); otherwise, continuing to execute the step (S01);
(S02) detecting whether the air compressor has no fault, if so, turning to an execution step (S03); otherwise, go to execute step (S01);
(S03) detecting whether the back pressure valve has no fault, if so, turning to an execution step (S04); otherwise, go to execute step (S01);
(S04) detecting whether the air pipeline has no falling fault, if so, turning to an execution step (S3), otherwise, turning to an execution step (S01).
Referring to fig. 4, the present embodiment discloses a fault monitoring and processing system for an intake air flow sensor of a fuel cell, including:
the fuel cell air system 1 comprises a pile, an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, an air inlet temperature pressure sensor and a flow sensor, wherein the air filter, the air compressor, the intercooler, the humidifier and the air inlet end of the pile are sequentially connected, the air outlet end of the pile, the humidifier and the back pressure valve are sequentially connected, the flow sensor is arranged on a pipeline between the air filter and the air compressor, and the air inlet temperature pressure sensor is arranged at the air inlet end of the pile;
the fault detection module 2 is used for detecting and sending whether the air inlet temperature pressure sensor, the air compressor, the back pressure valve and the air pipeline have faults or not;
the fuel cell controller 3 is used for receiving the actually measured air inlet pressure and temperature, the rotating speed of the air compressor, the air inlet flow, the opening degree of the back pressure valve and the fault signal, and carrying out corresponding calculation and logic processing;
the fault detection module 2, the air compressor, the back pressure valve, the air inlet temperature and pressure sensor and the flow sensor are all connected with the fuel cell controller 3, and the fuel cell inlet flow sensor fault monitoring processing system is configured to execute the steps of the fuel cell inlet flow sensor fault monitoring processing method.
In this embodiment, the fuel cell air system further includes a humidity sensor connected to the fuel cell controller.
The embodiment also discloses a vehicle comprising the fault monitoring and processing system of the fuel cell air inlet flow sensor.
The fuel cell air inlet flow sensor fault monitoring processing method, the system and the vehicle can monitor the working state of the flow sensor in real time based on the redundant design of the flow sensor, and replace the flow sensor to work until the fault is repaired after the flow sensor breaks down, thereby eliminating the potential safety hazard of the fuel cell caused by the fault of the flow sensor.
The foregoing describes in detail preferred embodiments of the present invention. It should be understood that numerous modifications and variations can be made in accordance with the concepts of the invention by one of ordinary skill in the art without undue burden. Therefore, all technical solutions which can be obtained by logic analysis, reasoning or limited experiments based on the prior art by the person skilled in the art according to the inventive concept shall be within the scope of protection defined by the claims.
Claims (8)
1. The fault monitoring and processing method for the fuel cell air inlet flow sensor is characterized by comprising the following steps:
(S1) powering up and finishing initialization;
(S2) detecting whether the air inlet temperature pressure sensor, the air compressor and the back pressure valve are all fault-free and whether the air pipeline is free of falling faults, if so, turning to an execution step (S3);
(S3) detecting whether there is a failure in the flow sensor; if yes, go to execute step (S7); otherwise, go to execute step (S4);
(S4) starting the fuel cell to operate, and monitoring the actual measurement flow Qa of the flow sensor in real time;
(S5) calculating an estimated air intake flow rate Qe;
(S6) judging whether the absolute value Qa-Qe is smaller than a calibration threshold value, if so, enabling the flow sensor to work normally, and ending the flow; otherwise, the measurement error of the flow sensor is overlarge, and the step (S7) is executed;
(S7) prompting a fault, and adopting the estimated air inlet flow Qe to replace the measured flow of the flow sensor in the follow-up operation until the fault is recovered;
the calculation formula of the estimated air intake flow Qe is as follows:
wherein: qe represents the estimated air intake flow; v represents the volume of an air inlet cavity of the electric pile; p represents the actual measurement of the air inlet pressure of the air inlet temperature pressure sensor; ps represents saturated steam pressure at different temperatures, and is obtained by inquiring a temperature-saturated steam pressure relation table; r represents a gas constant; ma represents the molar mass of dry air; t represents the actual measurement of the air-in temperature pressure sensor; n represents the actual measured rotating speed of the air compressor; x represents the actual measurement of the opening of the back pressure valve by the back pressure valve position sensor; h (n, x) represents relative humidity related to the rotating speed n of the air compressor and the opening x of the back pressure valve, the measured value of the internal humidity of the electric pile is filled into a relative humidity meter, and the relative humidity is obtained by positioning and interpolating the measured rotating speed n of the air compressor and the opening x of the back pressure valve; indicating and actually measuring air compressor rotationThe speed n and the correction coefficient related to the actual measured back pressure valve opening x are obtained by inquiring a calibrated air compressor rotating speed-back pressure valve opening-correction coefficient relation table;
the calibration steps of the air compressor rotating speed-back pressure valve opening-correction coefficient relation table are as follows:
(A1) Setting an air compressor rotating speed-back pressure valve opening-correction coefficient relation table, and setting m different air compressor rotating speed values n 1 、n 2 、···、n i 、···、n m And m different back pressure valve opening values x 1 、x 2 、···、x j 、···、x m The rotation speed values of m different air compressors and the opening values of m different back pressure valves form m operating points (n i ,x j ) And setting m x m operating points (n i ,x j ) The corresponding correction coefficientAre all equal to 1;
(A2) Selecting a first operating point (n i ,x j );
(A3) Acquiring relative humidity H (n, x), recording actual measurement air inlet pressure P, actual measurement air inlet temperature T, actual measurement air compressor rotating speed n, actual measurement air inlet flow Qa and actual measurement back pressure valve opening x, and calculating estimated air inlet flow Qe under the working condition point;
(A4) Comparing whether the difference between Qe and Qa is within a preset range;
if yes, go to execute step (A5);
otherwise, resetting the correction coefficient (n i ,x j ) Is transferred to the execution of step (A3);
(A5) Recording the correction coefficient (n i ,x j ) Turning to an execution step (S6);
(S6) whether all working condition points are calibrated is judged, if yes, the calibration is finished by the relation table of the rotating speed of the air compressor, the opening degree of the back pressure valve and the correction coefficient; otherwise, selecting the next working point (n i ,x j ) Go to step (A3).
2. The fuel cell intake air flow sensor failure monitoring processing method according to claim 1, characterized in that in step (S2), if not, step (S2) is continued.
3. The fuel cell intake air flow sensor failure monitoring processing method according to claim 2, characterized in that whether the difference between the comparison Qe and Qa is within a preset range, specifically performs the steps of:
judging whether the value of Qe-Qa/Qa is smaller than a preset threshold value.
4. A fuel cell intake air flow sensor failure monitoring processing method according to claim 3, characterized in that the preset threshold value is equal to 3%.
5. The method for monitoring and processing the faults of the fuel cell intake air flow sensor according to claim 1, 2, 3 or 4, wherein the steps of detecting whether the air intake temperature pressure sensor, the air compressor and the back pressure valve are both fault-free and whether the air pipeline is free from falling off are specifically performed:
(S01) detecting whether the air-in temperature and pressure sensor has no fault, if so, turning to an execution step (S02); otherwise, continuing to execute the step (S01);
(S02) detecting whether the air compressor has no fault, if so, turning to an execution step (S03); otherwise, go to execute step (S01);
(S03) detecting whether the back pressure valve has no fault, if so, turning to an execution step (S04); otherwise, go to execute step (S01);
(S04) detecting whether the air pipeline has no falling fault, if so, turning to an execution step (S3), otherwise, turning to an execution step (S01).
6. A fuel cell intake air flow sensor fault monitoring processing system, comprising:
the fuel cell air system (1) comprises a pile, an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, an air inlet temperature pressure sensor and a flow sensor, wherein the air filter, the air compressor, the intercooler, the humidifier and the air inlet end of the pile are sequentially connected, the air outlet end of the pile, the humidifier and the back pressure valve are sequentially connected, the flow sensor is arranged on a pipeline between the air filter and the air compressor, and the air inlet temperature pressure sensor is arranged at the air inlet end of the pile;
the fault detection module (2) is used for detecting and sending whether the air inlet temperature pressure sensor, the air compressor, the back pressure valve and the air pipeline have faults or not;
the fuel cell controller (3) is used for receiving the actually measured air inlet pressure and temperature, the rotating speed of the air compressor, the air inlet flow, the opening degree of the back pressure valve and fault signals, and carrying out corresponding calculation and logic processing;
the fault detection module (2), the air compressor, the back pressure valve, the air inlet temperature and pressure sensor and the flow sensor are all connected with a fuel cell controller (3), and the fuel cell inlet flow sensor fault monitoring processing system is configured to be capable of executing the steps of the fuel cell inlet flow sensor fault monitoring processing method according to any one of claims 1 to 5.
7. The fuel cell air intake flow sensor fault monitoring and handling system of claim 6, further comprising a humidity sensor coupled to the fuel cell controller.
8. A vehicle comprising the fuel cell intake air flow sensor failure monitoring processing system according to claim 6 or 7.
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