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My guess is that you are running into the Windows file pathname length limit. For Sonys, this is 201 characters, including the prefix (X:\database\media\books\). If the length is exceeded, then the driver starts pulling characters out of each component of the name until the name fits within the limit. The only way to avoid this is to use shorter names or to shorten the names yourself in consistent ways. The latter would require some interesting template programming, but it is possible.
As for question 2 - non-ascii characters in file names: the answer is no. For question 3, the unique calibre id is appended to be sure that the name cannot conflict with another file.
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