What I've done:
- I've imported all my products once (without any problems regarding the images)
- Deleted all of them and then deleted all files under media/catalog/products
- imported all my products again
- Now it creates two image entries in my product while only the first exists
- 1234.jpg (only this file exists)
- 1234_1.jpg (selected as default)
- Now it creates two image entries in my product while only the first exists
So i assume there is an cache, db entry, something which remembers the file which was there at some point.
Line which triggers the image import:
$this->product->addImageToMediaGallery($this->filepath, array('image', 'small_image', 'thumbnail'), true, false);