After another case of this happening, I did a search, and while I found a lot of suggestions about auto-grow with regards to adding new controls via the BD "Create xxx" menu and some about adding new controls into a Tab control on the FP, I'm surprised that I didn't see any comments/suggestions about how adding a control to the FP can cause an auto-grow oops since you can't really control where the new Terminal is added to the BD.
This is a bit of a frustration for me, I'll have written part the skeleton of my code, my structures in place and sized how I want them. I then swap to the FP to start adding more specific controls, I select the controls I want on the FP palette, drop them, swap to the BD and everything is messed up because some of the controls decided they were part of various BD structures and thus resized things. This isn't just auto-grow, I've had a case where the control was dropped into a case frame and while working with another control, the visible frame was changed, and I 'lost' the control terminal. I was able to find it by swapping to the FP and using 'find terminal' but was still a pain and a bother.
My suggestion is: New terminals added via the front panel are not added to any sub-diagrams in the BP, instead of semi-mimicking their location relative to the FP, just place them near the desired location that isn't already taken up. This way, the only way a terminal is added to a sub-diagram is when the user decides to add it to the sub-diagram.
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Available in LabVIEW NXG 1.0. All new controls/indicators placed on the front panel are always available in the same place on the diagram...the unplaced items tray.