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Yeah, I think that is what will have to be done. Right now the team is in a mindset where the control of mechanical parts are not part of their design. So the software guys are supposed to take the mechanicals final product and figure out ways to add sensors. Some devices are even given to us saying, "this can not run against the mechanical stop," without thought of where they could put a sensor. I'm sure all this is pretty typical.
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Sounds like your guys need to take a course or two in mechatronics. We require that all of our students undertake the "synergistic integration of mechanical design, sensors, and control" before we OK the design to be built.