While level matching of randomly selected drivers of the same model is a valid concern (and rarely done for any speaker), you've eluded to the far bigger imaging issue with line arrays, that being the inherent inability to image along the axis of the line (normally vertical). The theory behind line arrays is to produce the same sound wave, floor to ceiling and for that wave to only travel horizontally, therefore image height cannot be defined. And until the sound waves from each driver coalesces with adjacent sound waves there can be no single image either. So why worry about the relative subtly of driver matching? (This two dimensional propagation provides increased overall efficiency, OTOH smaller drivers are less efficient than larger ones.)
To produce a given spl at a defined distance in a defined room and at a given frequency you must displace a fixed amount of air. Except for horn loaded compression drivers and bass tuning of the rear waves found in horns, quarter wave pipes, and transmission lines you are looking at driver area and travel as the involved factors. Smaller drivers must travel farther to displace the same amount of air. As the time needed for travel distance increases dynamic response goes down. This is less of the problem as frequency increases, the number of drivers is increased, and/or as spl's decrease.
Quality control of drivers is a hit or miss proposition by brand, cost, or type.
Sorry, but I can't answer how modern designs allow for increase excursion. Good question. Hopefully one or more of the guys from AV123, DIY Cable, GR Research, etc. will respond.